Staple height indicator for powered surgical stapler

ABSTRACT

A surgical instrument includes a body assembly, a distally extending shaft assembly, and a distal stapling assembly configured to clamp, staple, and cut tissue. A first user feedback element is configured to visually inform a user of a first condition of the stapling assembly, and a second user feedback element is configured to visually inform the user of a second condition of the stapling assembly. A circuit board assembly includes a circuit board, a first light source configured to illuminate the first user feedback element, a second light source configured to illuminate the second user feedback element, and a light guide feature. The light guide feature is configured to direct light from the second light source toward the second user feedback element and simultaneously inhibit light emitted by the first light source from illuminating the second user feedback element.

PRIORITY

This application claims priority to U.S. Provisional Pat. App. No.62/815,678, entitled “Circular Surgical Stapler,” filed Mar. 8, 2019,the disclosure of which is incorporated by reference herein.

BACKGROUND

In some surgical procedures (e.g., colorectal, bariatric, thoracic,etc.), portions of a patient's digestive tract (e.g., thegastrointestinal tract and/or esophagus, etc.) may be cut and removed toeliminate undesirable tissue or for other reasons. Once the tissue isremoved, the remaining portions of the digestive tract may be coupledtogether in an end-to-end anastomosis, an end-to-side anastomosis, or aside-to-side anastomosis. The anastomosis may provide a substantiallyunobstructed flow path from one portion of the digestive tract to theother portion of the digestive tract, without also providing any kind ofleaking at the site of the anastomosis.

One example of an instrument that may be used to provide an anastomosisis a circular stapler. Some such staplers are operable to clamp down onlayers of tissue, cut through the clamped layers of tissue, and drivestaples through the clamped layers of tissue to substantially seal thelayers of tissue together near the severed ends of the tissue layers,thereby joining the two severed ends of the anatomical lumen together.The circular stapler may be configured to sever the tissue and seal thetissue substantially simultaneously. For instance, the circular staplermay sever excess tissue that is interior to an annular array of staplesat an anastomosis, to provide a substantially smooth transition betweenthe anatomical lumen sections that are joined at the anastomosis.Circular staplers may be used in open procedures or in endoscopicprocedures. In some instances, a portion of the circular stapler isinserted through a patient's naturally occurring orifice.

Examples of circular staplers are described in U.S. Pat. No. 5,205,459,entitled “Surgical Anastomosis Stapling Instrument,” issued Apr. 27,1993; U.S. Pat. No. 5,271,544, entitled “Surgical Anastomosis StaplingInstrument,” issued Dec. 21, 1993; U.S. Pat. No. 5,275,322, entitled“Surgical Anastomosis Stapling Instrument,” issued Jan. 4, 1994; U.S.Pat. No. 5,285,945, entitled “Surgical Anastomosis Stapling Instrument,”issued Feb. 15, 1994; U.S. Pat. No. 5,292,053, entitled “SurgicalAnastomosis Stapling Instrument,” issued Mar. 8, 1994; U.S. Pat. No.5,333,773, entitled “Surgical Anastomosis Stapling Instrument,” issuedAug. 2, 1994; U.S. Pat. No. 5,350,104, entitled “Surgical AnastomosisStapling Instrument,” issued Sep. 27, 1994; and U.S. Pat. No. 5,533,661,entitled “Surgical Anastomosis Stapling Instrument,” issued Jul. 9,1996; and U.S. Pat. No. 8,910,847, entitled “Low Cost Anvil Assembly fora Circular Stapler,” issued Dec. 16, 2014. The disclosure of each of theabove-cited U.S. patents is incorporated by reference herein.

Some circular staplers may include a motorized actuation mechanism.Examples of circular staplers with motorized actuation mechanisms aredescribed in U.S. Pub. No. 2015/0083772, entitled “Surgical Stapler withRotary Cam Drive and Return,” published Mar. 26, 2015, now abandoned;U.S. Pat. No. 9,936,949, entitled “Surgical Stapling Instrument withDrive Assembly Having Toggle Features,” issued Apr. 10, 2018; U.S. Pat.No. 9,907,552, entitled “Control Features for Motorized SurgicalStapling Instrument,” issued Mar. 6, 2018; and U.S. Pat. No. 9,713,469,entitled “Surgical Stapler with Rotary Cam Drive,” issued Jul. 25, 2017.The disclosure of each of the above-cited U.S. Patent Publications isincorporated by reference herein.

While various kinds of surgical stapling instruments and associatedcomponents have been made and used, it is believed that no one prior tothe inventor(s) has made or used the invention described in the appendedclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims which particularly pointout and distinctly claim this technology, it is believed this technologywill be better understood from the following description of certainexamples taken in conjunction with the accompanying drawings, in whichlike reference numerals identify the same elements and in which:

FIG. 1 depicts a perspective view of an exemplary circular stapler;

FIG. 2 depicts a perspective view of the circular stapler of FIG. 1,with a battery pack removed from a handle assembly and an anvil removedfrom a stapling head assembly;

FIG. 3 depicts a perspective view of the anvil of the circular staplerof FIG. 1;

FIG. 4 depicts another perspective view of the anvil of FIG. 3;

FIG. 5 depicts an exploded side elevational view of the anvil of FIG. 3;

FIG. 6 depicts a bottom plan view of an exemplary alternative anvil thatmay be used with the circular stapler of FIG. 1 in place of the anvil ofFIG. 3;

FIG. 7 depicts an enlarged bottom plan view of a portion of the anvil ofFIG. 6;

FIG. 8 depicts an enlarged perspective view of a portion of the anvil ofFIG. 6;

FIG. 9 depicts a perspective view of the stapling head assembly of thecircular stapler of FIG. 1;

FIG. 10 depicts a perspective cross-sectional view of an inner bodymember of the stapling head assembly of FIG. 9;

FIG. 11 depicts an exploded perspective view of the stapling headassembly of FIG. 9;

FIG. 12 depicts a perspective view of an exemplary alternative deckmember that may be incorporated into the stapling head assembly of FIG.9;

FIG. 13 depicts a top plan view of the deck member of FIG. 12;

FIG. 14A shows a side elevational view of the anvil of FIG. 3 at a firstlongitudinal position in relation to the stapling head assembly of FIG.9;

FIG. 14B shows a side elevational view of the anvil of FIG. 3 at asecond longitudinal position in relation to the stapling head assemblyof FIG. 9;

FIG. 15A depicts a cross-sectional side view of the distal end of thecircular stapler of FIG. 1, with a contact switch of the circularstapler in an open state;

FIG. 15B depicts a cross-sectional side view of the distal end of thecircular stapler of FIG. 1, with the contact switch of FIG. 15A movedinto a closed state by proximal translation of a trocar and an anvil ofthe circular stapler;

FIG. 16A depicts an enlarged cross-sectional side view of the contactswitch of FIG. 15A in the open state of FIG. 15A;

FIG. 16B depicts an enlarged cross-sectional side view of the contactswitch of FIG. 15A moved into the closed state of FIG. 15B by proximaltranslation of the trocar and the anvil of the circular stapler;

FIG. 17 depicts an exploded perspective view of the circular stapler ofFIG. 1, with portions of the shaft assembly shown separately from eachother;

FIG. 18 depicts a perspective view of the handle assembly of thecircular stapler of FIG. 1, with a housing portion omitted to revealinternal components of the handle assembly;

FIG. 19 depicts a perspective view of a stapling head actuation assemblyof the circular stapler of FIG. 1;

FIG. 20 depicts a perspective view of a cam follower of the staplinghead actuation assembly of FIG. 19;

FIG. 21 depicts another perspective view of the cam follower of FIG. 20;

FIG. 22 depicts a perspective view of a rotary cam of the stapling headactuation assembly of FIG. 19;

FIG. 23 depicts another perspective view of the rotary cam of FIG. 22;

FIG. 24A depicts a side elevational view of the stapling head actuationassembly of FIG. 19, with the rotary cam in a first angular position andthe cam follower in a first pivotal position;

FIG. 24B depicts a side elevational view of the stapling head actuationassembly of FIG. 19, with the rotary cam in a second angular positionand the cam follower in a second pivotal position;

FIG. 25A depicts a perspective view of the rotary cam of FIG. 22, arocker member, and a stop switch, with the rotary cam in a first angularposition and the rocker member in a first pivotal position;

FIG. 25B depicts a perspective view of the rotary cam of FIG. 22, therocker member of FIG. 25A, and the stop switch of FIG. 25A, with therotary cam in a fourth angular position and the rocker member in asecond pivotal position;

FIG. 26A depicts a schematic end view of the rotary cam of FIG. 22, thecam follower of FIG. 20, and the rocker member of FIG. 25A, with therotary cam in the first angular position, the cam follower in the firstpivotal position, and the rocker member in the first pivotal position;

FIG. 26B depicts a schematic end view of the rotary cam of FIG. 22 andthe cam follower of FIG. 20, with the rotary cam in the second angularposition, the cam follower in the second pivotal position, and therocker member of FIG. 25A in the first pivotal position;

FIG. 26C depicts a schematic end view of the rotary cam of FIG. 22 andthe cam follower of FIG. 20, with the rotary cam in a third angularposition, the cam follower in the second pivotal position, and therocker member of FIG. 25A in the first pivotal position;

FIG. 26D depicts a schematic end view of the rotary cam of FIG. 22, thecam follower of FIG. 20, and the rocker member of FIG. 25A, with therotary cam in a fourth angular position, the cam follower in a thirdpivotal position, and the rocker member in a second pivotal position;

FIG. 27A depicts a cross-sectional side view of the anvil of FIG. 3positioned within a first section of a digestive tract and the staplinghead assembly of FIG. 9 positioned in a second section of the digestivetract, with the anvil separated from the stapling head assembly;

FIG. 27B depicts a cross-sectional side view of the anvil of FIG. 3positioned within the first section of the digestive tract and thestapling head assembly of FIG. 9 positioned in the second section of thedigestive tract, with the anvil secured to the stapling head assembly;

FIG. 27C depicts a cross-sectional side view of the anvil of FIG. 3positioned within the first section of the digestive tract and thestapling head assembly of FIG. 9 positioned in the second section of thedigestive tract, with the anvil retracted toward the stapling headassembly to thereby clamp tissue between the anvil and the stapling headassembly;

FIG. 27D depicts a cross-sectional side view of the anvil of FIG. 3positioned within the first section of the digestive tract and thestapling head assembly of FIG. 9 positioned in the second section of thedigestive tract, with the stapling head assembly actuated to sever andstaple the clamped tissue;

FIG. 27E depicts a cross-sectional side view of the first and secondsections of the digestive tract of FIG. 27A joined together at anend-to-end anastomosis;

FIG. 28 depicts a perspective view of a bracket of the handle assemblyof FIG. 18;

FIG. 29 depicts a perspective view of an indicator member of the handleassembly of FIG. 18;

FIG. 30A depicts a perspective view of an anvil actuation assembly ofthe circular stapler of FIG. 1, an actuation rod in a first position;

FIG. 30B depicts a perspective view of the anvil actuation assembly ofFIG. 30A, with the actuation rod moved to a second position to engagethe bracket of FIG. 28;

FIG. 30C depicts a perspective view of the anvil actuation assembly ofFIG. 30A, with the actuation rod moved to a third position to retractthe bracket of FIG. 28 proximally;

FIG. 30D depicts a perspective view of the anvil actuation assembly ofFIG. 30A, with a safety trigger pivoted from a first position to asecond position;

FIG. 30E depicts a perspective view of the anvil actuation assembly ofFIG. 30A, with a firing trigger pivoted from a first position to asecond position;

FIG. 31 depicts a perspective view of the safety trigger of FIG. 30D andan associated upright member;

FIG. 32 depicts a perspective view of a user feedback feature of thehandle assembly of FIG. 18;

FIG. 33 depicts a perspective view of an exemplary alternative indicatormember that may be incorporated into the instrument of FIG. 1;

FIG. 34 depicts another perspective view of the indicator member of FIG.33;

FIG. 35 depicts a perspective view of an exemplary alternative bracketthat may be incorporated into the instrument of FIG. 1;

FIG. 36 depicts a perspective view of the indicator member of FIG. 33 incombination with the bracket of FIG. 35;

FIG. 37 depicts an exploded perspective view of the indicator member ofFIG. 33 with an exemplary alternative chassis that may be incorporatedinto the instrument of FIG. 1;

FIG. 38A depicts a side elevational view of the indicator member of FIG.33 coupled with the chassis of FIG. 37, with the indicator member in afirst angular position;

FIG. 38B depicts a side elevational view of the indicator member of FIG.33 coupled with the chassis of FIG. 37, with the indicator member in asecond angular position;

FIG. 38C depicts a side elevational view of the indicator member of FIG.33 coupled with the chassis of FIG. 37, with the indicator member in athird angular position;

FIG. 38D depicts a side elevational view of the indicator member of FIG.33 coupled with the chassis of FIG. 37, with the indicator member in afourth angular position

FIG. 39A depicts a side elevational view of the indicator member of FIG.33 and the bracket of FIG. 35, with the bracket in a first longitudinalposition and the indicator member in a first angular position;

FIG. 39B depicts a side elevational view of the indicator member of FIG.33 and the bracket of FIG. 35, with the bracket in a second longitudinalposition and the indicator member in the first angular position;

FIG. 39C depicts a side elevational view of the indicator member of FIG.33 and the bracket of FIG. 35, with the bracket in a third longitudinalposition and the indicator member in a second angular position;

FIG. 39D depicts a side elevational view of the indicator member of FIG.33 and the bracket of FIG. 35, with the bracket in a fourth longitudinalposition and the indicator member in a third angular position;

FIGS. 40A-40B depict a flow chart showing exemplary steps of operatingthe circular stapler of FIG. 1;

FIG. 41 depicts a perspective view of yet another exemplary alternativecircular stapler;

FIG. 42 depicts a perspective view of the circular stapler of FIG. 41,with a battery pack removed from a handle assembly of the circularstapler;

FIG. 43 depicts a perspective view of the battery pack of FIG. 42;

FIG. 44 depicts a partially exploded perspective view of the batterypack of FIG. 42;

FIG. 45A depicts a perspective view of the handle assembly of FIG. 42,with a casing removed from the handle assembly, and with the batterypack of FIG. 42 spaced apart from the handle assembly;

FIG. 45B depicts a perspective view of the handle assembly of FIG. 42,with a casing removed from the handle assembly, and with the batterypack of FIG. 42 coupled with the handle assembly;

FIG. 46 depicts a perspective view of the handle assembly of FIG. 42,with a casing removed from the handle assembly, and with a lower batteryhousing of the battery pack of FIG. 42 in a first position relative tothe handle assembly;

FIG. 47 depicts a detailed perspective view of the lower battery housingof FIG. 46 in the first position of FIG. 46, with a battery drain sledof the lower battery housing in a first position relative to a body ofthe lower battery housing;

FIG. 48 depicts another detailed perspective view of the lower batteryhousing of FIG. 46, with the battery drain sled of FIG. 47 in the firstposition of FIG. 47;

FIG. 49 depicts a perspective view of the handle assembly of FIG. 42,with a casing removed from the handle assembly, and with the lowerbattery housing of FIG. 46 moved distally to a second position relativeto the handle assembly, and with a drain activation rail of the handleassembly received within the lower battery housing in a first position;

FIG. 50 depicts a detailed perspective view of the lower battery housingof FIG. 46 in the second position of FIG. 49, with the battery drainsled of FIG. 47 remaining in the first position of FIG. 47, and with thedrain activation rail of FIG. 49 received within the lower batteryhousing in the first position of FIG. 49;

FIG. 51 depicts a perspective view of the handle assembly of FIG. 42,with a casing removed from the handle assembly, with the lower batteryhousing of FIG. 46 moved distally to a third position relative to thehandle assembly such that the drain activation rail of FIG. 50 is movedto a second position such that the drain activation rail engages thebattery drain sled of FIG. 47;

FIG. 52 depicts a detailed perspective view of the lower battery housingof FIG. 46 in the third position of FIG. 51, with the battery drain sledof FIG. 47 remaining in the first position of FIG. 47, and with thedrain activation rail of FIG. 49 received within the lower batteryhousing in the second position of FIG. 51 such that the drain activationrail engages the battery drain sled;

FIG. 53 depicts a perspective view of the handle assembly of FIG. 42,with a casing removed from the handle assembly, with the lower batteryhousing of FIG. 46 moved distally to a fourth position relative to thehandle assembly such that the drain activation rail of FIG. 50 is movedto a third position such that the drain activation rail drives thebattery drain sled of FIG. 47 proximally to a second position;

FIG. 54 depicts a detailed perspective view of the lower battery housingof FIG. 46 in the fourth position of FIG. 53, with the drain activationrail of FIG. 49 received within the lower battery housing in the thirdposition of FIG. 53 such that the drain activation rail drives thebattery drain sled of FIG. 47 moved into the second position of FIG. 53;

FIG. 55 depicts a perspective view of the handle assembly of FIG. 42,with a casing removed from the handle assembly, with the lower batteryhousing of FIG. 46 removed from the handle assembly such that the drainactivation rail of FIG. 50 is removed from the lower battery housing,and with the battery drain sled of FIG. 47 remaining in the secondposition of FIG. 53 such that a drain contact of the battery pack ofFIG. 52 is biased toward a positive contact of the battery pack;

FIG. 56 depicts a detailed perspective view of the handle assembly ofFIG. 42, with the lower battery housing of FIG. 46 removed from thehandle assembly, and with the battery drain sled of FIG. 47 remaining inthe second position of FIG. 53 such that the drain contact of FIG. 55 isbiased toward the positive contact of FIG. 55;

FIG. 57 depicts a detailed perspective view of the handle assembly ofFIG. 42, with the lower battery housing of FIG. 46 removed from thehandle assembly, and with the battery drain sled of FIG. 47 remaining inthe second position of FIG. 53 such that the drain contact of FIG. 55 isbiased toward the positive contact of FIG. 55;

FIG. 58 depicts a schematic view of an exemplary battery drain circuitthat may be incorporated into the circular stapler of FIG. 1;

FIG. 59A depicts a perspective view of a firing trigger and motoractivation module of the handle assembly of FIG. 18, with the firingtrigger in a non-actuated position;

FIG. 59B depicts a perspective view of the firing trigger and motoractivation module of FIG. 59A, with the firing trigger in an actuatedposition;

FIG. 60 depicts a schematic view of an exemplary control circuit thatmay be incorporated into the instrument of FIG. 1;

FIG. 61 depicts a detailed view of the coil spring of FIG. 18;

FIG. 62 depicts a bottom view of the trocar actuation rod of FIG. 17,the right chassis portion and the nut of FIG. 18, the bracket of FIG.35, the left chassis portion of FIG. 37, and a first exemplaryalternative coil spring;

FIG. 63 depicts a detailed view of the coil spring of FIG. 62;

FIG. 64 depicts a detailed view of a second exemplary alternative coilspring;

FIG. 65 depicts a detailed view of a third exemplary alternative coilspring;

FIG. 66 depicts a perspective view of the bracket of FIG. 35 coupledwith the coil spring of FIG. 61 using an exemplary slidable coupling;

FIG. 67 depicts a detailed perspective portion of the bracket, the coilspring, and the slidable coupling of FIG. 66;

FIG. 68 depicts an exploded perspective view of the slidable couplingseparated from the bracket and the coil spring of FIG. 66;

FIG. 69 depicts a detailed perspective view of the slidable coupling ofFIG. 68;

FIG. 70 depicts an exploded perspective view of the trocar actuation rodof FIG. 17, the nut and coil spring of FIG. 18, the bracket of FIG. 35,and an exemplary guide bushing;

FIG. 71 depicts a detailed perspective view of the guide bushing of FIG.70;

FIG. 72 depicts a perspective view of the bracket and the coil spring ofFIG. 62, but with the bracket including a centering feature;

FIG. 73 depicts a perspective view of the bracket and the coil spring ofFIG. 62, but with the coil spring disposed in a sleeve;

FIG. 74 depicts a detailed perspective view of the coil spring and thesleeve of FIG. 73;

FIG. 75 depicts a perspective view of the bracket of FIG. 35 disposedwithin the left chassis portion;

FIG. 76 depicts a detailed perspective view of the bracket and the leftchassis portion of FIG. 75;

FIG. 77 depicts a perspective view of the bracket and the left chassisportion of FIG. 76 but from another angle;

FIG. 78 depicts a rear elevational view of the bracket and left chassisportion of FIG. 75, but with the left chassis portion including alongitudinal rib;

FIG. 79 depicts a right perspective view of the bracket and the leftchassis portion of FIG. 78;

FIG. 80 depicts a perspective view of a protrusion of a safety triggerinteracting with a track bounded by first and second detents of rightchassis portion of FIG. 18;

FIG. 81 depicts a perspective view of the protrusion of the safetytrigger of FIG. 80 interacting with another exemplary right chassisportion that includes a raised portion between the first and seconddetents;

FIG. 82 depicts a partially exploded perspective view of a portion ofthe handle assembly of the surgical stapler of FIG. 1, with a housingportion of the handle assembly omitted, and showing a lens member and acover plate of the user feedback feature of FIG. 32 separated from thehandle assembly;

FIG. 83 depicts an enlarged perspective view of the lens member and amain circuit board assembly of the handle assembly of FIG. 82;

FIG. 84 depicts a perspective view of an exemplary alternative maincircuit board assembly configured for use with the handle assembly ofFIG. 82;

FIG. 85 depicts a side cross-sectional view of a distal portion of themain circuit board assembly of FIG. 84 and a proximal portion of thelens member of the user feedback feature of FIG. 82, showing a proximallight guide feature of the lens member positioned to receive a distallight guide feature of the main circuit board assembly;

FIG. 86 depicts a perspective view of an exemplary circuit boardassembly configured for use with the handle assembly of FIG. 82 andhaving a conformal coating;

FIG. 87 depicts a perspective view of another exemplary circuit boardassembly configured for use with the handle assembly of FIG. 82 andhaving a conformal coating;

FIG. 88 depicts a top plan view of a portion of another exemplary userfeedback feature configured for use with the handle assembly of FIG. 82and having a cover plate and a slidable shutter configured to adjust a“green zone” visible through a window of the cover plate;

FIG. 89 depicts a perspective view of the cover plate and the slidableshutter of FIG. 88, with a portion of the cover plate showntransparently to reveal features of the slidable shutter;

FIG. 90 depicts a side elevational view of the cover plate and theslidable shutter of FIG. 88, positioned atop a distal end of a maincircuit board assembly of the surgical stapler of FIG. 1;

FIG. 91 depicts a top plan view of a portion of another exemplary userfeedback feature configured for use with the handle assembly of FIG. 82and having a cover plate and a ratcheting shutter configured to adjust a“green zone” visible through a window of the cover plate;

FIG. 92A depicts a top elevational view of an exemplary user feedbackfeature configured for use with the surgical stapler of FIG. 1, showingthe user feedback feature in a first state in which a proximal end ofthe visible “green zone” is at a first longitudinal location beforebeing adjusted;

FIG. 92B depicts a top elevational view of the user feedback feature ofFIG. 90A, showing the user feedback feature in a second state in whichthe proximal end of the visible “green zone” has been adjustedproximally to a second longitudinal location to align with an indicatorneedle;

FIG. 93 depicts a perspective view of an exemplary alternative indicatormember having a screw and a nut configured to enable adjustment of anangular position of the indicator member relative to a translatablebracket of the handle assembly of FIG. 82;

FIG. 94 depicts a side elevational view of a portion of the handleassembly of the surgical stapler of FIG. 1, with various componentsomitted from view, showing the indicator member of FIG. 93 incombination with a translatable bracket;

FIG. 95 depicts a perspective view of an exemplary alternative firingtrigger having an elastically deformable paddle configured for use withthe surgical instrument of FIG. 1;

FIG. 96A depicts a side elevational view of a portion of the handleassembly of the surgical instrument of FIG. 1, with various componentsomitted from view, showing the firing trigger of FIG. 95 in anunactuated position; and

FIG. 96B depicts a side elevational view of a portion of the handleassembly of the surgical instrument of FIG. 1, showing the firingtrigger of FIG. 95 in an actuated position.

The drawings are not intended to be limiting in any way, and it iscontemplated that various embodiments of the technology may be carriedout in a variety of other ways, including those not necessarily depictedin the drawings. The accompanying drawings incorporated in and forming apart of the specification illustrate several aspects of the presenttechnology, and together with the description serve to explain theprinciples of the technology; it being understood, however, that thistechnology is not limited to the precise arrangements shown.

DETAILED DESCRIPTION

The following description of certain examples of the technology shouldnot be used to limit its scope. Other examples, features, aspects,embodiments, and advantages of the technology will become apparent tothose skilled in the art from the following description, which is by wayof illustration, one of the best modes contemplated for carrying out thetechnology. As will be realized, the technology described herein iscapable of other different and obvious aspects, all without departingfrom the technology. Accordingly, the drawings and descriptions shouldbe regarded as illustrative in nature and not restrictive.

This application incorporates by reference the disclosures of U.S. Pub.No. 2015/0083772, entitled “Surgical Stapler with Rotary Cam Drive andReturn,” published on Mar. 26, 2015, now abandoned; U.S. Pat. No.9,907,552, entitled “Control Features for Motorized Surgical StaplingInstrument,” issued on Mar. 6, 2018; U.S. Pub. No. 2016/0374672,entitled “Method of Applying an Annular Array of Staples to Tissue,”published on Dec. 29, 2016; issued as U.S. Pat. No. 10,478,189 on Nov.19, 2019; U.S. Pub. No. 2018/0132853, entitled “Circular Stapler withRecessed Deck,” published May 17, 2018; issued as U.S. Pat. No.10,980,542 on Apr. 20, 2021; U.S. Pub. No. 2018/0132849, entitled“Staple Forming Pocket Configurations for Circular Surgical StaplerAnvil,” published May 17, 2018; U.S. Pub. No. 2018/0310938, entitled“Hysteresis Removal Feature in Surgical Stapling Instrument,” publishedNov. 1, 2018, issued as U.S. Pat. No. 10,695,068 on Jun. 30, 2020, andU.S. Pub. No. 2018/0310939, entitled “Liquid-Immune Trigger Circuit forSurgical Instrument,” published Nov. 1, 2018, issued as U.S. Pat. No.10,729,444 on Aug. 4, 2020.

I. Overview of Exemplary Circular Stapling Surgical Instrument

FIGS. 1-2 depict an exemplary surgical circular stapling instrument (10)that may be used to provide an end-to-end, side-to-side, or end-to-sideanastomosis between two sections of an anatomical lumen such as aportion of a patient's digestive tract. Instrument (10) of this examplecomprises a handle assembly (100), a shaft assembly (200), a staplinghead assembly (300), and an anvil (400). Handle assembly (100) comprisesa casing (110) defining an obliquely oriented pistol grip (112). In someversions, pistol grip (112) is perpendicularly oriented. In some otherversions, pistol grip (112) is omitted. Handle assembly (100) furtherincludes a user feedback feature (114) that permits viewing of a movableindicator needle (1526) as will be described in greater detail below. Insome versions, a series of hash marks, colored regions, and/or otherfixed indicators are positioned adjacent to user feedback feature (114)in order to provide a visual context for indicator needle (1526),thereby facilitating operator evaluation of the position of needle(1526) within user feedback feature (114). Various suitable alternativefeatures and configurations for handle assembly (100) will be apparentto those of ordinary skill in the art in view of the teachings herein.

Instrument (10) of the present example further includes a battery pack(120). Battery pack (120) is operable to provide electrical power to amotor (161) in pistol grip (112) as will be described in greater detailbelow. Battery pack (120) is removable from handle assembly (100). Inparticular, as shown in FIGS. 1-2, battery pack (120) may be insertedinto a socket (116) defined by casing (110). Once battery pack (120) isfully inserted in socket (116), latches (122) of battery pack (120) mayresiliently engage interior features of casing (110) to provide a snapfit. To remove battery pack (120), the operator may press latches (122)inwardly to disengage latches (122) from the interior features of casing(110) then pull battery pack (120) proximally from socket (116). Itshould be understood that battery pack (120) and handle assembly (100)may have complementary electrical contacts, pins and sockets, and/orother features that provide paths for electrical communication frombattery pack (120) to electrically powered components in handle assembly(100) when battery pack (120) is inserted in socket (116). It shouldalso be understood that, in some versions, battery pack (120) isunitarily incorporated within handle assembly (100) such that batterypack (120) cannot be removed from handle assembly (100).

Shaft assembly (200) extends distally from handle assembly (100) andincludes a preformed bend. In some versions, the preformed bend isconfigured to facilitate positioning of stapling head assembly (300)within a patient's colon. Various suitable bend angles or radii that maybe used will be apparent to those of ordinary skill in the art in viewof the teachings herein. In some other versions, shaft assembly (200) isstraight, such that shaft assembly (200) lacks a preformed bend. Variousexemplary components that may be incorporated into shaft assembly (200)will be described in greater detail below.

Stapling head assembly (300) is located at the distal end of shaftassembly (200). As shown in FIGS. 1-2 and as will be described ingreater detail below, anvil (400) is configured to removably couple withshaft assembly (200), adjacent to stapling head assembly (300). As willalso be described in greater detail below, anvil (400) and stapling headassembly (300) are configured to cooperate to manipulate tissue in threeways, including clamping the tissue, cutting the tissue, and staplingthe tissue. A knob (130) at the proximal end of handle assembly (100) isrotatable relative to casing (110) to provide precise clamping of thetissue between anvil (400) and stapling head assembly (300). When asafety trigger (140) of handle assembly (100) is pivoted away from afiring trigger (150) of handle assembly (100), firing trigger (150) maybe actuated to thereby provide cutting and stapling of the tissue.

II. Exemplary Anvil

A. Overview

In the following discussion of anvil (400), the terms “distal” and“proximal” (and variations thereof) will be used with reference to theorientation of anvil (400) when anvil (400) is coupled with shaftassembly (200) of instrument (10). Thus, proximal features of anvil(400) will be closer to the operator of instrument (10); while distalfeatures of anvil (400) will be further from the operator of instrument(10).

As best seen in FIGS. 3-5, anvil (400) of the present example comprisesa head (410) and a shank (420). Head (410) includes a proximal surface(412) that defines a plurality of staple forming pockets (414). Stapleforming pockets (414) are arranged in two concentric annular arrays inthe present example. In some other versions, staple forming pockets(414) are arranged in three or more concentric annular arrays. Stapleforming pockets (414) are configured to deform staples as the staplesare driven into staple forming pockets (414). For instance, each stapleforming pocket (414) may deform a generally “U” shaped staple into a “B”shape as is known in the art. As best seen in FIG. 4, proximal surface(412) terminates at an inner edge (416), which defines an outer boundaryof an annular recess (418) surrounding shank (420).

Shank (420) defines a bore (422) and includes a pair of pivoting latchmembers (430) positioned in bore (422). As best seen in FIG. 5, eachlatch member (430) includes a “T” shaped distal end (432), a roundedproximal end (434), and a latch shelf (436) located distal to proximalend (434). “T” shaped distal ends (432) secure latch members (430)within bore (422). Latch members (430) are positioned within bore (422)such that proximal ends (434) are positioned at the proximal ends oflateral openings (424), which are formed through the sidewall of shank(420). Lateral openings (424) thus provide clearance for proximal ends(434) and latch shelves (436) to deflect radially outwardly from thelongitudinal axis defined by shank (420). However, latch members (430)are configured to resiliently bias proximal ends (434) and latch shelves(436) to pivot radially inwardly toward the longitudinal axis defined byshank (420). Latch members (430) thus act as retaining clips. Thisallows anvil (400) to be removably secured to a trocar (330) of staplinghead assembly (300) as will be described in greater detail below. Whenshank (420) is secured to trocar (330) and trocar (330) is retractedproximally, the inner diameter of bore (314) in inner core member (312)of body member (310) laterally constrains latch members (430) tomaintain engagement between latch shelves (436) and proximal surface(338) of head (334) of trocar (330). This engagement prevents anvil(400) from being released from trocar (330) during firing of staplinghead assembly (300). It should be understood, however, that latchshelves (436) are merely optional. Anvil (400) may be removably securedto a trocar (330) using any other suitable components, features, ortechniques.

As best seen in FIGS. 3-4, shank (420) of the present example includes aset of longitudinally extending splines (426) that are spaced aboutshank (420) in an angular array. The proximal end of each spline (426)includes a respective lead-in edge (428). As described in greater detailbelow, splines (426) are configured to engage corresponding splines(316) of an inner body member (310) of stapling head assembly (300) inorder to consistently provide a predetermined angular alignment betweenanvil (400) and stapling head assembly (300). As also described below,this angular alignment may ensure that staple forming pockets (414) ofanvil (400) are consistently angularly aligned appropriately with stapleopenings (324) of stapling head assembly (300). Thus, in the presentexample, splines (426) are precisely and consistently positioned inrelation to staple forming pockets (414). In versions where head (410)and shank (420) are initially formed as separate pieces and then laterjoined together, the machine or other device that is used to join head(410) and shank (420) together may have appropriate indexingcapabilities in order to reliably and consistently achieve the properangular positioning of head (410) and shank (420) to thereby provideprecise and consistent positioning of splines (426) in relation tostaple forming pockets (414). Various suitable ways in which suchresults may be achieved will be apparent to those of ordinary skill inthe art in view of the teachings herein. In some other versions, head(410) and shank (420) are formed together simultaneously, as a singleunitary construction.

In some instances, it may be desirable to change the configuration andarrangement of staple forming pockets (414) in anvil (400). It should beunderstood that reconfiguring and rearranging staple forming pockets(414) may result in reconfiguration and rearrangement of staples (90)that are formed by staple forming pockets (414). For instance, theconfiguration and arrangement of staple forming pockets (414) may affectthe structural integrity of an anastomosis (70) that is secured bystaples (90). In addition, the configuration and arrangement of stapleforming pockets (414) may affect the hemostasis that is achieved at ananastomosis (70) that is secured by staples (90). The followingdescription relates to several exemplary variations of anvil (400),providing staple forming pocket configurations and arrangements thatdiffer from those of staple forming pockets (414).

It should be understood that the various alternatives to anvil (400)described below may be readily used with instrument (10), in place ofanvil (400). It should also be understood that, in some instances, theconfiguration and arrangement of staple openings (324) in deck member(320) may need to be varied in order to complement the configuration andarrangement of the alternative staple forming pockets described below.Various suitable ways in which the alternatives to anvil (400) describedbelow may be incorporated into instrument (10) will be apparent to thoseof ordinary skill in the art in view of the teachings herein.

B. Exemplary Three-Dimensional Staple Formation Features

FIGS. 6-8 show an exemplary alternative anvil (500) that may be usedwith a modified version of instrument (10). Anvil (500) of this exampleis configured and operable just like anvil (400), except for thedifferences described below. Anvil (500) of the present examplecomprises a proximal surface (506) that defines an inner annular array(502) of staple forming pockets (510, 530) and an outer annular array(504) of staple forming pockets (550, 570). A chamfered edge (508)extends about the outer perimeter of proximal surface (506). It shouldbe understood that anvil (500) may be secured to trocar (330), thatproximal surface (506) may be used to compress tissue against decksurface (322), and that staple driver (352) may drive staples (90)through tissue into staple forming pockets (510, 530, 550, 570) in orderto thereby form staples (90) in the tissue.

As best seen in FIGS. 7-8, each staple forming pocket (510) comprises astaple entry surface (512) and a staple exit surface (514). Surfaces(512, 514) are contiguous with each other and define a concave recess.The concave recess formed by surfaces (512, 514) is further defined byan inner wall (516), a first outer wall (518), a second outer wall(520), and a third outer wall (522). In the present example, walls (516,518, 520, 522) are each substantially flat. Wall (518) defines arelatively narrow, tapered gap with wall (516). Wall (522) defines arelatively wide gap with wall (516). Wall (520) is obliquely angled,providing an inwardly sloped transition from wall (522) to wall (518).Thus, walls (518, 520, 522) together provide a dogleg configuration. Theedge connecting wall (516) with wall (522) is substantially straight inthis example. Similarly, the edge connecting wall (516) with wall (518)is substantially straight in this example.

It should be understood that when a first leg of staple (90) is driveninto staple forming pocket (510), the first leg first encounters stapleentry surface (512), bends generally toward the second leg of staple(90) along a first plane that is orthogonal to the axis of the unformedfirst leg, and then bends proximally back generally toward the crown ofstaple (90). In addition, the first leg will eventually encounter wall(520), which will provide a cam surface bending the first leg along asecond plane that is orthogonal to the axis of the unformed first leg.In particular, wall (520) and then wall (518) will deflect the first legradially inwardly toward the central axis of anvil (500). Thus, stapleforming pocket (510) will ultimately deflect a first leg of a staple(90) proximally and radially inwardly. Wall (516) will restrict thedegree to which the first leg of staple (90) deflects radially inwardly.

Each staple forming pocket (530) comprises a staple entry surface (532)and a staple exit surface (534). Surfaces (532, 534) are contiguous witheach other and define a concave recess. The concave recess formed bysurfaces (532, 534) is further defined by an outer wall (536), a firstinner wall (538), a second inner wall (540), and a third inner wall(542). In the present example, walls (536, 538, 540, 542) are eachsubstantially flat. Wall (538) defines a relatively narrow, tapered gapwith wall (536). Wall (542) defines a relatively wide gap with wall(536). Wall (540) is obliquely angled, providing an outwardly slopedtransition from wall (542) to wall (538). Thus, walls (538, 540, 542)together provide a dogleg configuration. The edge connecting wall (536)with wall (542) is substantially straight in this example. Similarly,the edge connecting wall (536) with wall (538) is substantially straightin this example.

It should be understood that when a second leg of staple (90) is driveninto staple forming pocket (530), the second leg first encounters stapleentry surface (532), bends generally toward the first leg of staple (90)along a first plane that is orthogonal to the axis of the unformedsecond leg, and then bends proximally back generally toward the crown ofstaple (90). In addition, the second leg will eventually encounter wall(540), which will provide a cam surface bending the second leg along asecond plane that is orthogonal to the axis of the unformed second leg.In particular, wall (540) and then wall (538) will deflect the secondleg radially outwardly away from the central axis of anvil (500). Thus,staple forming pocket (530) will ultimately deflect a second leg of astaple (90) proximally and radially outwardly. Wall (536) will restrictthe degree to which the second leg of staple (90) deflects radiallyoutwardly.

Each staple forming pocket (550) comprises a staple entry surface (552)and a staple exit surface (554). Surfaces (552, 554) are contiguous witheach other and define a concave recess. The concave recess formed bysurfaces (552, 554) is further defined by an outer wall (556), a firstinner wall (558), a second inner wall (560), and a third inner wall(562). In the present example, walls (556, 558, 560, 562) are eachsubstantially flat. Wall (558) defines a relatively narrow, tapered gapwith wall (556). Wall (562) defines a relatively wide gap with wall(556). Wall (560) is obliquely angled, providing an outwardly slopedtransition from wall (562) to wall (558). Thus, walls (558, 560, 562)together provide a dogleg configuration. The edge connecting wall (556)with wall (562) is substantially straight in this example. Similarly,the edge connecting wall (556) with wall (558) is substantially straightin this example.

It should be understood that when a second leg of staple (90) is driveninto staple forming pocket (550), the second leg first encounters stapleentry surface (552), bends generally toward the first leg of staple (90)along a first plane that is orthogonal to the axis of the unformedsecond leg, and then bends proximally back generally toward the crown ofstaple (90). In addition, the second leg will eventually encounter wall(560), which will provide a cam surface bending the second leg along asecond plane that is orthogonal to the axis of the unformed second leg.In particular, wall (560) and then wall (558) will deflect the secondleg radially outwardly away from the central axis of anvil (500). Thus,staple forming pocket (550) will ultimately deflect a second leg of astaple (90) proximally and radially outwardly. Wall (556) will restrictthe degree to which the second leg of staple (90) deflects radiallyoutwardly.

Each staple forming pocket (570) comprises a staple entry surface (572)and a staple exit surface (574). Surfaces (572, 574) are contiguous witheach other and define a concave recess. The concave recess formed bysurfaces (572, 574) is further defined by an inner wall (576), a firstouter wall (578), a second outer wall (580), and a third outer wall(582). In the present example, walls (576, 578, 580, 582) are eachsubstantially flat. Wall (578) defines a relatively narrow, tapered gapwith wall (576). Wall (582) defines a relatively wide gap with wall(576). Wall (580) is obliquely angled, providing an inwardly slopedtransition from wall (582) to wall (578). Thus, walls (578, 580, 582)together provide a dogleg configuration. The edge connecting wall (576)with wall (582) is substantially straight in this example. Similarly,the edge connecting wall (576) with wall (578) is substantially straightin this example.

It should be understood that when a first leg of staple (90) is driveninto staple forming pocket (570), the first leg first encounters stapleentry surface (572), bends generally toward the second leg of staple(90) along a first plane that is orthogonal to the axis of the unformedfirst leg, and then bends proximally back generally toward the crown ofstaple (90). In addition, the first leg will eventually encounter wall(580), which will provide a cam surface bending the first leg along asecond plane that is orthogonal to the axis of the unformed first leg.In particular, wall (580) and then wall (578) will deflect the first legradially inwardly toward the central axis of anvil (500). Thus, stapleforming pocket (570) will ultimately deflect a first leg of a staple(90) proximally and radially inwardly. Wall (576) will restrict thedegree to which the first leg of staple (90) deflects radially inwardly.

As best seen in FIG. 6, staple forming pockets (510, 530, 550, 570) arearranged such that a radius line (R_(L)) extending outwardly from thecenter of anvil (500) passes through the region of staple entry surface(512) of staple forming pocket (510) and through the region of stapleentry surface (552) of staple forming pocket (550). Thus, staple formingpockets (510, 550) overlap along a radial dimension. In addition,another radius line (R_(L)) extending outwardly from the center of anvil(500) passes through the region of staple entry surface (532) of stapleforming pocket (530) and through the region of entry surface (572) ofstaple forming pocket (570). Thus, staple forming pockets (530, 570)overlap along a radial dimension. In addition, another radius line(R_(L)) extending outwardly from the center of anvil (500) passesthrough the region of exit surface (574) of staple forming pocket (570)and through the region of exit surface (554) of staple forming pocket(550). Thus, staple forming pockets (550, 570) overlap along a radialdimension. It should also be understood that staple forming pockets(550, 570) in each pair of pockets (550, 570) are interlocking in thisconfiguration. In addition, another radius line (R_(L)) extendingoutwardly from the center of anvil (500) passes through the region ofstaple exit surface (514) of staple forming pocket (510) and through theregion of exit surface (534) of staple forming pocket (530). Thus,staple forming pockets (510, 530) overlap along a radial dimension. Itshould also be understood that staple forming pockets (510, 530) in eachpair of pockets (510, 530) are interlocking in this configuration.

In the present example, inner annular array (502) and outer annulararray (504) are configured similarly, such that the inner-most pocket(510) in each pair of inner pockets (510, 530) is on the left-hand side(in the view of FIG. 7) of the pair of pockets (510, 530); and such thatthe inner-most pocket (570) in each pair of outer pockets (550, 570) ison the left-hand side (in the view of FIG. 7) of the pair of pockets(550, 570).

Also, in the present example, the end of wall (536) associated withstaple entry surface (532) includes a bent region (537), which bendsslightly inwardly toward the central region of anvil (500). It should beunderstood that this bent region (537) may be formed in order tomaintain a minimum distance between wall (536) and wall (576), therebymaintaining a minimum distance between staple forming pocket (530) andstaple forming pocket (570), which may further provide more reliablemanufacturing of anvil (500). In addition, bent region (537) may providedifferent behavior of the second leg of the staple (90) that is formedby staple forming pocket (530). Such different behavior may relate todeflections in anvil (500) and/or a tilt that might result in the firstand second legs of a given staple (90) contacting corresponding surfaces(512, 532) at different times during actuation of stapling head assembly(300).

It should also be understood that the presence of bent region (537)provides staple forming pocket (530) with a structural configurationthat makes staple forming pocket (530) unique relative to the otherstaple forming pockets (510, 550, 570). By contrast, the structuralconfiguration of staple forming pocket (510) is identical to thestructural configuration of staple forming pocket (570); while thestructural configuration of staple forming pocket (550) is the mirroredinverse of the structural configuration of staple forming pockets (510,570).

In the present example, the spacing between pockets (510, 530) in eachpair of pockets (510, 530) is equal to the spacing between pockets (550,570) in each pair of pockets (550, 570). Thus, staples (90) formed bypockets (510, 530) will have the same crown width as staples formed bypockets (550, 570). In some other versions, however, the spacing betweenpockets (510, 530) in each pair of pockets (510, 530) is smaller thanthe spacing between pockets (550, 570) in each pair of pockets (550,570). In such versions, pockets (550, 570) may be used to form staples(90) having a longer crown width than staples (90) that are formed usingpockets (510, 530). As another merely illustrative variation, thespacing between pockets (510, 530) in each pair of pockets (510, 530)may be larger than the spacing between pockets (550, 570) in each pairof pockets (550, 570). In such versions, pockets (550, 570) may be usedto form staples (90) having a shorter crown width than staples (90) thatare formed using pockets (510, 530). In other words, where at least twoannular arrays of staples are formed, staples (90) in one array may havea larger, smaller, or same crown width as staples (90) in anotherannular array.

As also seen in FIG. 7, staple forming pockets (510, 530) are arrangedsuch that they are not fully centered along a circumferential line (COextending along surface (506) at a constant radius from the center ofanvil (500). The outermost regions of staple entry surfaces (512, 532)are radially centered along the same circumferential line (CO. However,staple forming pocket (510) is oriented substantially obliquely relativeto circumferential line (CL), such that staple exit surface (514) ispositioned substantially radially inwardly from circumferential line(CO. By contrast, staple exit surface (534) is positioned substantiallyalong, with a portion position slightly radially outwardly from,circumferential line (CO. In other words, while staple forming pocket(530) is substantially aligned along circumferential line (CL), stapleforming pocket (510) is substantially tilted radially inwardly relativeto circumferential line (CL), with the outermost regions of staple entrysurfaces (512, 532) being radially centered along a circumferential line(CO.

While the views depicted in FIGS. 7-8 only show a portion of the fullcircumference of anvil (500), it should be understood that thestructures depicted in FIGS. 7-8 extend along the full circumference ofanvil (500). The views of FIGS. 7-8 are simply being provided as anenlargement to show the structure in further detail, and are notintended to suggest that the depicted structures are only located in alimited angular range along the circumference of anvil (500).

Those of ordinary skill in the art will understand that staples formedby anvil (500) will have a three-dimensional profile, where the legs areangularly offset from a plane passing through a crown of the staple; inaddition to being bent generally toward each other. By way of exampleonly, the staples formed using anvil (500) may have an appearancesimilar to at least some of the staples shown and described in U.S. Pat.No. 10,092,292, entitled “Staple Forming Features for Surgical StaplingInstrument,” issued Oct. 9, 2018, the disclosure of which isincorporated by reference herein. By way of further example only, thestaples formed using anvil (500) may have an appearance similar to atleast some of the staples shown and described in U.S. Pub. No.2018/0132849, entitled “Staple Forming Pocket Configurations forCircular Surgical Stapler Anvil,” published May 17, 2018, the disclosureof which is incorporated by reference herein.

In addition to or in lieu of the foregoing, anvil (400) may be furtherconstructed and operable in accordance with at least some of theteachings of U.S. Pat. Nos. 5,205,459; 5,271,544; 5,275,322; 5,285,945;5,292,053; 5,333,773; 5,350,104; 5,533,661; and/or U.S. Pat. No.8,910,847, the disclosures of which are incorporated by referenceherein. Still other suitable configurations will be apparent to one ofordinary skill in the art in view of the teachings herein.

III. Exemplary Stapling Head Assembly

A. Overview

As best seen in FIGS. 9-11, stapling head assembly (300) of the presentexample is coupled to a distal end of shaft assembly (200) and comprisesa body member (310) and a slidable staple driver member (350). Bodymember (310) includes a distally extending cylindraceous inner coremember (312). Body member (310) is fixedly secured to an outer sheath(210) of shaft assembly (200). Body member (310) and outer sheath (210)thus serve together as a mechanical ground for stapling head assembly(300).

As shown in FIG. 10, inner core member (312) of body member (310)defines a bore (314). A plurality of longitudinally extending splines(316) are equidistantly spaced in an angular array within bore (314).The distal ends of splines (316) include lead-in edges (318) that areconfigured to complement lead-in edges (428) of splines (426) on shank(420) of anvil (400). In particular, after shank (420) is secured totrocar (330) as described in greater detail below, and as anvil (400) isthereafter retracted proximally relative to stapling head assembly (300)as also described in greater detail below, lead-in edges (318, 428) maycooperatively engage each other to drive anvil (400) to rotate relativeto trocar (330) to angularly align splines (426) of anvil (400) with thegaps between splines (316) of body member (310). The gaps betweensplines (316) may be configured to have a width that is substantiallyequal to the width of splines (426). In this manner, when splines (426)of anvil (400) are positioned within the gaps between splines (316) ofbody member (310), anvil (400) may achieve a predetermined angularalignment relative to stapling head assembly (300). This predeterminedangular alignment may ensure that staple openings (324) of deck member(320) are precisely aligned with corresponding staple forming pockets(414, 510, 530) of anvil (400). Thus, splines (316, 426) are configuredto cooperate with each other to ensure that staples ejected throughstaple openings (324) are accurately driven into corresponding stapleforming pockets (414, 510, 530) on a consistent basis, regardless of theangular orientation of anvil (400) relative to stapling head assembly(300) at the time anvil (400) is initially secured to trocar (330).

Trocar (330) is positioned coaxially within inner core member (312) ofbody member (310). As will be described in greater detail below, trocar(330) is operable to translate distally and proximally relative to bodymember (310) in response to rotation of knob (130) relative to casing(110) of handle assembly (100). Trocar (330) comprises a shaft (332) anda head (334). Head (334) includes a pointed tip (336) and an inwardlyextending proximal surface (338). Shaft (332) thus provides a reducedouter diameter just proximal to head (334), with proximal surface (338)providing a transition between that reduced outer diameter of shaft(332) and the outer diameter of head (334). While tip (336) is pointedin the present example, tip (336) is not sharp. Tip (336) will thus noteasily cause trauma to tissue due to inadvertent contact with tissue.Head (334) and the distal portion of shaft (332) are configured forinsertion in bore (422) of anvil (400). Proximal surface (338) and latchshelves (436) have complementary positions and configurations such thatlatch shelves (436) engage proximal surface (338) when shank (420) ofanvil (400) is fully seated on trocar (330). Anvil (400) is thus securedto trocar (330) through a snap fit due to latch members (430).

Staple driver member (350) is operable to actuate longitudinally withinbody member (310) in response to activation of motor (161) as will bedescribed in greater detail below. Staple driver member (350) includestwo distally presented concentric annular arrays of staple drivers(352). Staple drivers (352) are arranged to correspond with thearrangement of staple forming pockets (414) described above. Thus, eachstaple driver (352) is configured to drive a corresponding staple into acorresponding staple forming pocket (414) when stapling head assembly(300) is actuated. It should be understood that the arrangement ofstaple drivers (352) may be modified just like the arrangement of stapleforming pockets (414) as described above. Staple driver member (350)also defines a bore (354) that is configured to coaxially receive innercore member (312) of body member (310). An annular array of studs (356)project distally from a distally presented surface surrounding bore(354).

A cylindraceous knife member (340) is coaxially positioned within stapledriver member (350). Knife member (340) includes a distally presented,sharp circular cutting edge (342). Knife member (340) is sized such thatknife member (340) defines an outer diameter that is smaller than thediameter defined by the inner annular array of staple drivers (352).Knife member (340) also defines an opening that is configured tocoaxially receive inner core member (312) of body member (310). Anannular array of openings (346) formed in knife member (340) isconfigured to complement the annular array of studs (356) of stapledriver member (350), such that knife member (340) is fixedly secured tostaple driver member (350) via studs (356) and openings (346). By way ofexample only, studs (356) may be heat staked to knife member (340) usingtechniques known in the art. Other suitable structural relationshipsbetween knife member (340) and staple driver member (350) will beapparent to those of ordinary skill in the art in view of the teachingsherein.

A deck member (320) is fixedly secured to body member (310). Deck member(320) includes a distally presented deck surface (322) defining twoconcentric annular arrays of staple openings (324). Staple openings(324) are arranged to correspond with the arrangement of staple drivers(352) and staple forming pockets (414) described above. Thus, eachstaple opening (324) is configured to provide a path for a correspondingstaple driver (352) to drive a corresponding staple through deck member(320) and into a corresponding staple forming pocket (414) when staplinghead assembly (300) is actuated. It should be understood that thearrangement of staple openings (324) may be modified just like thearrangement of staple forming pockets (414) as described above. Itshould also be understood that various structures and techniques may beused to contain staples within stapling head assembly (300) beforestapling head assembly (300) is actuated. Such structures and techniquesthat are used to contain staples within stapling head assembly (300) mayprevent the staples from inadvertently falling out through stapleopenings (324) before stapling head assembly (300) is actuated. Varioussuitable forms that such structures and techniques may take will beapparent to those of ordinary skill in the art in view of the teachingsherein.

As best seen in FIG. 9, deck member (320) defines an inner diameter thatis just slightly larger than the outer diameter defined by knife member(340). Deck member (320) is thus configured to allow knife member (340)to translate distally to a point where cutting edge (342) is distal todeck surface (322).

B. Exemplary Tissue Gripping Features

It may be desirable to provide a version of stapling head assembly (300)that includes features that enhance gripping of tissue during actuationof stapling head assembly (300), thereby promoting successful tissuecutting and staple deployment, without increasing the risk of damagingthe patient's tissue as stapling head assembly (300) slides along thetissue during positioning of stapling head assembly (300). FIGS. 12-13show an example of a deck member (600) that provides enhanced tissuegripping effects without increasing the risk of tissue damage. Deckmember (600) may be readily incorporated into stapling head assembly(300) in place of deck member (320).

Deck member (600) of this example includes a first deck surface (622), asecond deck surface (630), and two concentric annular arrays of stapleopenings (624). Staple openings (624) are arranged to correspond withthe arrangement of staple drivers (352) and staple forming pockets (414)described above. Thus, each staple opening (624) is configured toprovide a path for a corresponding staple driver (352) to drive acorresponding staple through deck member (600) and into a correspondingstaple forming pocket (414) when a stapling head assembly (300)incorporating deck member (600) is actuated. Deck member (600) definesan inner diameter that is just slightly larger than the outer diameterdefined by knife member (340). Deck member (600) is thus configured toallow knife member (340) to translate distally to a point where cuttingedge (342) is distal to the plane of second deck surface (630).

In the present example, an outer edge (620) spans around the fullcircumference of deck member (600) with a consistent surface geometry.In the present example, outer edge (620) is configured to prevent outeredge (620) from snagging on tissue. In some versions, outer edge (620)has a curved profile. In some other versions, outer edge (620) has achamfered profile. Alternatively, outer edge (620) may have any othersuitable kind of profile.

Second deck surface (630) is proud relative to first deck surface (622),such that first deck surface (622) is recessed relative to second decksurface (630). As shown, second deck surface (630) fully surrounds eachand every staple opening (624), including the inner array of stapleopenings (624) and the outer array of staple openings (624). However,first deck surface (622) extends inwardly between staple openings (624)of the outer array of staple openings (624), thereby creating gaps (626)in second deck surface (630) between staple openings (624) of the outerarray of staple openings (624).

A plurality of recesses (670) are spaced between the staple openings(624) of the inner annular array of staple openings (624). Recesses(670) of the present example are generally shaped like isoscelestriangles, with each triangle being defined by a pair of straight walls(674) having equal length and an inner annular wall (672). The vertexesformed by walls (674) are positioned at the radially outermost points ofrecesses (670). In particular, these vertexes are located at radialpositions corresponding to the same circumference at which the angularlyoutermost points of staple openings (624) are located. In other words,these vertexes of recesses (670) and corresponding points of stapleopenings (624) are all positioned at the same radial distance along thesame circumference in this example. Alternatively, the position andconfiguration of recesses (670) may have any other suitable relationshipwith the position and configuration of staple openings (624).

Recesses (670) of the present example are joined together by channels(680) which are defined between inner annular wall (672) and respectiveopposing annular walls (676). Walls (672, 676) are parallel with eachother and are closely positioned relative to each other, such thatchannels (680) are substantially small in comparison to recesses (670).

Gaps (626), recesses (670), and channels (680) are configured to receivetissue as tissue is being compressed against deck surfaces (622, 630) byanvil (400) as described above. In particular, when anvil (400) isactuated via knob (130) to compress tissue between anvil (400) and decksurfaces (622, 630), portions of the compressed tissue will enter gaps(626), recesses (670), and channels (680). By having some of the tissueenter gaps (626), recesses (670), and channels (680), this may reducethe total pressure that would otherwise be applied to the tissue if thetissue were being compressed against a consistently flat deck surfacelike deck surface (322). The pressure on tissue is thus concentratedonly in the areas where pressure is actually needed—immediately adjacentto staple openings (624). By reducing the total pressure on the tissue,deck member (600) may reduce the risk of the tissue from becomingfractured by over-compression. In addition to reducing the totalpressure on tissue, the entry of tissue portions in gaps (626), recesses(670), and channels (680) may provide a grip on the compressed tissuethat is greater than the grip that could otherwise be achieved using aconsistently flat deck surface like deck surface (322). The enhancedgrip of tissue may promote cleaner cutting by knife member (340) andalso promote more successful deployment of staples (90) in the tissue.Thus, the presence of gaps (626), recesses (670), and channels (680) mayboth reduce the risk of over-compression of tissue and promote greatersuccess in cutting and stapling the tissue.

In the present example, gaps (626), recesses (670), and channels (680)all extend to substantially the same depth relative to second decksurface (630). In some other versions, gaps (626), recesses (670), andchannels (680) extend to different depths relative to second decksurface (630). For instance, gaps (626) may extend to greater depthsthan recesses (670) relative to second deck surface (630) or vice versa.It should also be understood that gaps (626) may alternate depthsrelative to second deck surface (630), such that gaps (626) alternatebetween a relatively shallow gap (626) and a relatively deep gap (626)along at least a portion of the angular range of deck member (600).Similarly, recesses (670) may alternate depths relative to second decksurface (630), such that recesses (670) alternate between a relativelyshallow recess (670) and a relatively deep recess (670) along at least aportion of the angular range of deck member (600). As yet another merelyillustrative variation, the depth of a given gap (626) or recess (670)may vary within that particular gap (626) or recess (670). For instance,the radially innermost region of a given gap (626) may be deeper orshallower than the radially outermost region of that same gap (626).Similarly, the region of each recess (670) near the vertex may be deeperor shallower than the region of each recess (670) near inner annularwall (672). Other suitable variations that may be provided in the depthof gaps (626), recesses (670), and/or channels (680) relative to seconddeck surface (630) will be apparent to those of ordinary skill in theart in view of the teachings herein.

Inner annular wall (672) extends consistently along the fullcircumference of deck member (600). In particular, the height of theuppermost edge of inner annular wall (672) is consistent along the fullcircumference of deck member (600). The uppermost edge of inner annularwall (672) is thus configured to provide consistent pressure against theadjacent annular region of tissue as the tissue is being compressedagainst deck member (600) by anvil (400). This application of consistentpressure against the adjacent annular region of tissue may furtherassist in clean cutting of the tissue by knife member (340),particularly since knife member (340) will be severing the tissue rightnext to the uppermost edge of inner annular wall (672). In the presentexample, the uppermost edge of inner annular wall (672) is substantiallyflush with second deck surface (630). In some other variations, theuppermost edge of inner annular wall (672) is proud or raised relativeto second deck surface (630). In still other variations, the uppermostedge of inner annular wall (672) is recessed or lower relative to seconddeck surface (630).

C. Exemplary Anvil Coupling Detection

In some versions of instrument (10) it may desirable to provideinstrument (10) with features that are configured to indicate properand/or improper attachment of anvil (400) to trocar (330) of staplinghead assembly (300). For instance, if anvil (400) is not properlyattached to trocar (330), an operator may receive audible and/or tactilefeedback indicating improper attachment. Additionally, if anvil (400) isproperly attached to trocar (330), an operator may receive audible,tactile, and/or visible feedback indicating proper attachment. Inaddition or in the alternative, features may be configured to preventfiring of stapling head assembly (300) unless anvil (400) is properlyattached to trocar (330). For instance, if anvil (400) is not properlyattached to trocar (330), stapling head assembly (300) may be preventedfrom firing. If anvil (400) is properly attached to trocar (330), firingof stapling head assembly (300) may be enabled. Various examples of suchfeatures will be described in greater detail below; while other exampleswill be apparent to those of ordinary skill in the art in view of theteachings herein. Moreover, the following teachings may be applied todevices that are used in various other contexts.

In the example shown in FIGS. 14A-14B, trocar (330) includes a coloredregion (333) that is longitudinally positioned at a location wherecolored region (333) is exposed before shank (420) is fully seated ontrocar (330) (FIG. 14A); and covered when shank (420) is fully seated ontrocar (330) (FIG. 14B). Colored region (333) may be colored using acolor (e.g., orange) that is easily visible in relation to adjacentregions of trocar (330) and shank (420). When coupling shank (420) withtrocar (330), the operator may observe colored region (333) to ensurethat the entire colored region (333) is obscured by shank (420) beforeattempting to retract the combination of trocar (330) and anvil (400)relative to stapling head assembly (300). If the operator continues tosee even a portion of colored region (333), the operator may continuepressing anvil (400) onto trocar (330) until colored region (333) iscompletely obscured by shank (420).

Even when trocar (330) includes a visual feedback feature such ascolored region (333) to assist the operator with proper seating of anvil(400) on trocar (330), it may still be desirable to include a sensorfeature that is operable to detect whether anvil (400) is properlyseated on trocar (330). To that end, FIGS. 15A-16B depict an exemplaryswitch assembly (2600) that is incorporated into stapling head assembly(300) in the present example. Switch assembly (2600) includes a domeswitch (2610) and a resilient actuator spring (2602). Actuator spring(2602) is secured within a cavity (2606) formed within body member(310). Dome switch (2610) is positioned between a pair of flanges (2612,2614) of actuator spring (2602) such that movement of flange (2612)toward flange (2614) will actuate dome switch (2610).

When anvil (400) is properly secured to trocar (330) and is retractedproximally as described herein, anvil (400) causes movement of flange(2612) toward flange (2614) so as to actuate dome switch (2610).Actuation of dome switch (2610) may provide audible, tactile, and/orvisible feedback to an operator indicating proper attachment. Varioussuitable features that may be used to provide such a response toactuation of dome switch (2610) will be apparent to those of ordinaryskill in the art in view of the teachings herein. In addition, in thepresent example actuation of dome switch (2610) may enables firing ofstapling head assembly (300). In other words, unless dome switch (2610)has been actuated, stapling head assembly (300) may not be fired in thepresent example.

After anvil (400) is secured to trocar (330), the operator then rotatesknob (130) to cause trocar (330) and anvil (400) to retract proximallyas described above. When trocar (330) and anvil (400) are properlysecured to one another, the proximal retraction of trocar (330) andanvil (400) compresses the tissue of tubular anatomical structures (20,40) between surfaces (412, 322) of anvil (400) and stapling headassembly (300) as described herein. When trocar (330) and anvil (400)are not properly secured to one another, trocar (330) is retractedproximally without anvil (400), such that the tissue of tubularanatomical structures (20, 40) remains uncompressed. When trocar (330)and anvil (400) are properly secured to one another, as trocar (330) andanvil (400) are retracted proximally, a proximal end of shank (420) ofanvil (400) engages a raised portion (2604) of flange (2612) of actuatorspring (2602) and thereby drives flange (2612) toward flange (2614),thereby actuating dome switch (2610) as shown in FIGS. 15B and 16B.

In the present example, dome switch (2610) is not actuated immediatelyupon proper seating of shank (420) on trocar (330). Instead, trocar(330) and anvil (400) have to be retracted proximally relative tostapling head assembly (300) by at least some distance before domeswitch (2610) is actuated. In the present example, dome switch (2610) isactuated before anvil (400) reaches the “green zone” as describedherein. In some other variations, dome switch (2610) is not actuateduntil after anvil (400) reaches the distal-most boundary of the “greenzone” as described herein.

As mentioned above, the actuation of dome switch (2610) may provideaudible, tactile, and/or visible feedback to an operator indicatingproper attachment. Moreover, such actuation of dome switch (2610)enables firing of stapling head assembly (300). In other words, unlessdome switch (2610) has been actuated, stapling head assembly (300) maynot be fired. An exemplary way in which dome switch (2610) may beintegrated into a control circuit (2700) will be described in greaterdetail below with reference to FIG. 60. Other examples will be apparentto those of ordinary skill in the art in view of the teachings herein.

In addition to or in lieu of the foregoing, stapling head assembly (300)may be further constructed and operable in accordance with at least someof the teachings of U.S. Pat. Nos. 5,205,459; 5,271,544; 5,275,322;5,285,945; 5,292,053; 5,333,773; 5,350,104; 5,533,661; and/or U.S. Pat.No. 8,910,847, the disclosures of which are incorporated by referenceherein. Still other suitable configurations will be apparent to one ofordinary skill in the art in view of the teachings herein.

IV. Exemplary Drive Assemblies

FIG. 17 shows various components of shaft assembly (200), which couplescomponents of stapling head assembly (300) with components of handleassembly (100). In particular, and as noted above, shaft assembly (200)includes an outer sheath (210) that extends between handle assembly(100) and body member (310). In the present example, outer sheath (210)is rigid and includes a preformed curved section as noted above.

Shaft assembly (200) further includes a trocar actuation rod (220) and atrocar actuation band assembly (230). The distal end of trocar actuationband assembly (230) is fixedly secured to the proximal end of shaft(332) of trocar (330). The proximal end of trocar actuation bandassembly (230) is fixedly secured to the distal end of trocar actuationrod (220). It should therefore be understood that trocar (330) willtranslate longitudinally relative to outer sheath (210) in response totranslation of trocar actuation band assembly (230) and trocar actuationrod (220) relative to outer sheath (210). Trocar actuation band assembly(230) is configured to flex such that trocar actuation band assembly(230) may follow along the preformed curve in shaft assembly (200) astrocar actuation band assembly (230) is translated longitudinallyrelative to outer sheath (210). However, trocar actuation band assembly(230) has sufficient column strength and tensile strength to transferdistal and proximal forces from trocar actuation rod (220) to shaft(332) of trocar (330). Trocar actuation rod (220) is rigid. A clip (222)is fixedly secured to trocar actuation rod (220) and is configured tocooperate with complementary features within handle assembly (100) toprevent trocar actuation rod (220) from rotating within handle assembly(100) while still permitting trocar actuation rod (220) to translatelongitudinally within handle assembly (100). Trocar actuation rod (220)further includes a coarse helical threading (224) and a fine helicalthreading (226). Details regarding the movement of trocar actuation rod(220) will be described in greater detail below.

Shaft assembly (200) further includes a stapling head assembly driver(240) that is slidably received within outer sheath (210). The distalend of stapling head assembly driver (240) is fixedly secured to theproximal end of staple driver member (350). The proximal end of staplinghead assembly driver (240) is secured to a drive bracket (250) via a pin(242). It should therefore be understood that staple driver member (350)will translate longitudinally relative to outer sheath (210) in responseto translation of stapling head assembly driver (240) and drive bracket(250) relative to outer sheath (210). Stapling head assembly driver(240) is configured to flex such that stapling head assembly driver(240) may follow along the preformed curve in shaft assembly (200) asstapling head assembly driver (240) is translated longitudinallyrelative to outer sheath (210). However, stapling head assembly driver(240) has sufficient column strength to transfer distal forces fromdrive bracket (250) to staple driver member (350). Details regarding themovement of drive bracket (250) will be described in greater detailbelow.

While not shown in FIG. 17, it should be understood that shaft assembly(200) may further include one or more spacer elements within outersheath (210). Such spacer elements may be configured to support trocaractuation band assembly (230) and/or stapling head assembly driver (240)as trocar actuation band assembly (230) and/or stapling head assemblydriver (240) translate through outer sheath (210). For instance, suchspacer elements may prevent trocar actuation band assembly (230) and/orstapling head assembly driver (240) from buckling as trocar actuationband assembly (230) and/or stapling head assembly driver (240) translatethrough outer sheath (210). Various suitable forms that such spacerelements may take will be apparent to those of ordinary skill in the artin view of the teachings herein.

As shown in FIG. 18, handle assembly (100) includes several componentsthat are operable to actuate anvil (400) and stapling head assembly(300). Handle assembly (100) also includes components that are operableto selectively lock out triggers (140, 150) based on the position ofanvil (400) relative to stapling head assembly (300). When triggers(140, 150) are locked out, firing trigger (150) is prevented frominitiating actuation of stapling head assembly (300). Thus, firingtrigger (150) is only operable to initiate actuation of stapling headassembly (300) when the position of anvil (400) relative to staplinghead assembly (300) is within a predefined range. The components ofhandle assembly (100) that provide the foregoing operability will bedescribed in greater detail below.

A. Exemplary Anvil Actuation Assembly

Knob (130) protrudes proximally from casing (110) of handle assembly andis rotatable relative to casing (110). As shown in FIG. 19, a nut (160)is secured to the distal end of knob (130). In the present example, nut(160) is fixedly secured to the distal end of knob (130) such that nut(160) will rotate unitarily with knob (130). Nut (160) and knob (130)are configured to cooperate with trocar actuation rod (220) to therebytranslate trocar actuation rod (220) longitudinally relative to casing(110) in response to rotation of nut (160) and knob (130) relative tocasing (110). As noted above, trocar (330) will translate longitudinallyrelative to outer sheath (210) in response to translation of trocaractuation rod (220) relative to outer sheath (210) and casing (110).

The proximal portion of trocar actuation rod (220) is positioned withinhandle assembly (100) to engage nut (160) and knob (130). In particular,trocar actuation rod (220) is positioned within handle assembly (100)such that coarse helical threading (224) will selectively engage athread engagement feature (not shown) within the interior of nut (160);and such that fine helical threading (226) will selectively engage athread engagement feature (not shown) within the interior of knob (130).In some versions, the thread engagement feature of nut (160) comprisesan inwardly directed tab; while the thread engagement feature of knob(130) comprises a helical threading. Other suitable forms that suchthread engagement features may take will be apparent to those ofordinary skill in the art in view of the teachings herein.

In the present example, when nut (160) and knob (130) are rotatedrelative to casing (110), trocar actuation rod (220) travels proximallythrough a first range of longitudinal motion where coarse helicalthreading (224) is engaged with nut (160) to provide a relatively rapidrate of translation. Fine helical threading (226) is not engaged withknob (130) during this range of motion. When nut (160) and knob (130)are further rotated relative to casing (110) after trocar actuation rod(220) completes the first range of motion, trocar actuation rod (220)will continue to travel proximally through a second range oflongitudinal motion where fine helical threading (226) is engaged withknob (130) to provide a relatively slow rate of translation. Thus,trocar actuation rod (220) will translate proximally through a sequenceof rapid translation followed by slow translation, based on engagementbetween coarse helical threading (224) and nut (160) followed byengagement between fine helical threading (226) and knob (130).

It should be understood that when anvil (400) is coupled with trocar(330), rotation of knob (130) will provide corresponding translation ofanvil relative to stapling head assembly (300). It should also beunderstood that knob (130) may be rotated in a first angular direction(e.g., clockwise) to retract anvil (400) toward stapling head assembly(300); and in a second angular direction (e.g., counterclockwise) toadvance anvil (400) away from stapling head assembly (300). Knob (130)may thus be used to adjust the gap distance (d) between opposingsurfaces (412, 322) of anvil (400) and stapling head assembly (300)until a suitable gap distance (d) has been achieved as shown in FIG. 27Cand as described in greater detail below.

B. Exemplary Stapling Head Actuation Assembly

FIGS. 19-26D show various components that are operable to actuatestapling head assembly (300). These components include motor (161), agearbox (162), a rotary cam member (700), a cam follower (1600), drivebracket (250) and stapling head assembly driver (240). Gearbox (162) iscoupled with a drive shaft of motor (161) and is further coupled withcam member (700). Activation of motor (161) thus causes rotation of cammember (700) via gearbox (162). By way of example only, gearbox (162)may comprise a multi-stage planetary gearbox. Various suitableconfigurations that may be used for gearbox (162) will be apparent tothose of ordinary skill in the art in view of the teachings herein. Cammember (700) is configured to interact with cam follower (1600) to pivotcam follower (1600) in two angular directions about a pin (118) as willbe described in greater detail below. Pin (118) is coupled with achassis (e.g., chassis (3690) described below that as shown includesleft and right chassis portions (3691, 3693)), which is located withincasing (110). A bushing (701) provides rotary support to cam member(700) relative to the chassis in casing (110).

Cam follower (1600) is pivotably coupled with drive bracket (250) via apair of integral pins (1602), which are received in complementarynotches (252) of drive bracket (250). As shown in FIGS. 20-21, camfollower (1600) includes a first bearing feature (1604) and a secondbearing feature (1610). First bearing feature (1604) consists of arounded, horizontally extending surface. Second bearing feature (1610)is shaped like a quarter-pie defined by a straight vertical surface(1612), a horizontally extending surface (1614), and a curved surface(1616). Second bearing feature (1610) projects proximally relative tofirst bearing feature (1604).

FIGS. 22-23 show cam member (700) in greater detail. Cam member (700)comprises a distal face (702), a distally projecting post (704), and anouter circumferential surface (706). A first cam feature (710) and asecond cam feature (720) project distally from distal face (702). Post(704) engages bushing (701). First cam feature (710) comprises a firstsurface region (712), a second surface region (714), and a third surfaceregion (716). First surface region (712) is convexly defined by arelatively large radius of curvature, such that first surface region(712) is nearly flat. Second surface region (714) is convexly defined bya progressively increasing radius of curvature. Third surface region(716) is concavely defined by a relatively large radius of curvature. Inaddition to projecting distally from distal face (702), second camfeature (720) projects outwardly from outer circumferential surface(706). Second cam feature (720) includes a first surface region (722)and a second surface region (724). First surface region (722) issubstantially flat while second surface region (724) is concavelycurved. The origin of the radius of curvature for each curved surfaceregion (712, 714, 716, 724) is offset from the center of post (704).

FIGS. 24A-24B show the general interaction between cam follower (1600)and first and second cam features (710, 720), though this interactionwill be described in greater detail below with reference to FIGS.14A-14D. As cam member (700) is rotated from the position shown in FIG.24A to the position shown in FIG. 24B, first cam feature (710) bearsagainst first bearing feature (1604) of cam follower (1600), causing camfollower to pivot about pin (118). In the view shown in FIGS. 24A-24B,cam follower (1600) pivots counterclockwise as cam member (700) isrotated from the position shown in FIG. 24A to the position shown inFIG. 24B. As can be seen in the transition from FIG. 24A to FIG. 24B,this counterclockwise pivoting of cam follower (1600) drives drivebracket (250) and stapling head assembly driver (240) distally, therebyactuating stapling head assembly (300). As cam member (700) continues torotate in the same direction back toward the position shown in FIG. 24A,second cam feature (720) engages and bears against second bearingfeature (1610) of cam follower (1600), causing cam follower (1600) topivot clockwise about pin (118). This clockwise pivoting of cam follower(1600) about pin (118) retracts drive bracket (250) and stapling headassembly driver (240) proximally back toward the position shown in FIG.24A.

Referring back to FIGS. 22-23, a third cam feature (730) projectsoutwardly from outer circumferential surface (706). Third cam feature(730) comprises a first surface region (732) and a second surface region(734). First surface region (732) is flat and is oriented generallytangentially relative to outer circumferential surface (706). Secondsurface region (732) is also flat and is oriented radially outwardlyrelative to outer circumferential surface (706). Third cam feature (730)is configured to interact with a rocker member (800) as shown in FIGS.13A-13B. Rocker member (800) comprises an integral pin (802), a bearingmember (804), and a paddle (806). Pin (802) is pivotably coupled withthe chassis in casing (110), such that rocker member (800) is pivotablewithin casing (110) about the longitudinal axis defined by pin (802).Bearing member (804) is configured to interact with third cam feature(730) as will be described in greater detail below. Paddle (806) isconfigured to actuate a switch buttons (192) of a motor stop module(190) as will also be described in greater detail below.

FIG. 25A shows cam member (700) in the same position as shown in FIG.24A. At this stage, second surface region (734) of third cam feature(730) is adjacent to bearing member (804) of rocker member (800). FIG.25B shows cam member (700) in a position where cam member (700) has beenrotated past the position shown in FIG. 24B and back toward the positionshown in FIG. 24A. However, cam member (700) has not completed a fullrevolution. At the stage shown in FIG. 25B, first surface region (732)has engaged and borne against bearing member (804), thereby pivotingrocker member (800) about the longitudinal axis defined by pin (802).This has caused paddle (806) to actuate switch buttons (192) of motorstop module (190). Motor stop module (190) reverses the polarity ofelectrical power provided to motor (161) when switch buttons (192) areactuated. This results in stopping activation of motor (161) once anactuation stroke of stapling head assembly (300) has been completed. Byway of example only, motor stop module (190) may be configured andoperable in accordance with at least some of the teachings of U.S. Pat.No. 9,907,552, issued Mar. 6, 2018, the disclosure of which isincorporated by reference herein. Other suitable configurations will beapparent to those of ordinary skill in the art in view of the teachingsherein.

FIGS. 26A-26D schematically depict the interaction between cam member(700), features of cam follower (1600), and features of rocker member(800) as cam member (700) rotates. It should be understood that therotation of cam member (700) throughout the stages shown in FIGS.26A-26D is driven by motor (161) and gearbox (162). FIG. 26A shows cammember (700) in the same position as shown in FIGS. 24A and 25A. At thisstage, first bearing feature (1604) of cam follower (1600) is positionedon first surface region (712) and bearing member (804) or rocker member(800) is adjacent to second surface region (734) of third cam feature(730). Also at this stage, knife member (340) and staple driver member(350) are in proximal positions, such that stapling head assembly (300)is in a non-actuated state. As cam member (700) is rotated to theposition shown in FIG. 26B, second surface region (714) bears againstbearing member (1604), thereby driving bearing member (1604) upwardly.This causes cam follower (1600) to pivot about pin (118) to the positionshown in FIG. 24B. Cam follower (1600) thus drives knife member (340)and staple driver member (350) distally via drive bracket (250) andstapling head assembly driver (240). Stapling head assembly (300) isthus in an actuated state at the stage shown in FIG. 26B. In someversions, cam member (700) rotates through an angular range ofapproximately 270° in order to transition stapling head assembly (300)from the non-actuated state to the actuated state.

After stapling head assembly (300) has been actuated, cam member (700)continues to rotate to the position shown in FIG. 26C. At this stage,first surface region (722) of second cam member (720) begins to engagecurved surface (1616) of second bearing feature (1610) of cam follower(1600). As cam member (700) continues to rotate to the position shown inFIG. 26D, second surface region (724) engages curved surface (1616) ofsecond bearing feature (1610), driving second bearing feature (1610)downwardly. This causes cam follower (1600) to pivot about pin (118)back from the position shown in FIG. 24B toward the position shown inFIG. 24A. Cam follower (1600) thus drives knife member (340) and stapledriver member (350) proximally via drive bracket (250) and stapling headassembly driver (240). In addition, first surface region (732) hasengaged and borne against bearing member (804), thereby pivoting rockermember (800) about the longitudinal axis defined by pin (802) at thestage shown in FIG. 26D. Rocker member (800) is thus in the same statein FIG. 26D as shown in FIG. 25B. Motor stop module (190) has thus beenactuated at the stage shown in FIG. 26D.

It should be understood from the foregoing that cam member (700) isoperable to drive knife member (340) and staple driver member (350)distally, then drive knife member (340) and staple driver member (350)proximally and actuate motor stop module (190) by rotating in a singleangular direction through the range of motion shown in FIGS. 26A-26D. Inthe present example, cam member (700) provides the full operationalsequence depicted in FIGS. 26A-26D and described above by rotatingthrough an angular range of motion of approximately 355°. Moreparticularly, and by way of further example only, the first 270° ofrotation of cam member (700) may provide the distal movement of knifemember (340) and staple driver member (350); while the remaining 85° ofrotation of cam member (700) may provide the proximal movement of knifemember (340) and staple driver member (350) and the actuation of motorstop module (190). Other suitable ways in which knife member (340),staple driver member (350), and motor stop module (190) may be actuatedwill be apparent to those of ordinary skill in the art in view of theteachings herein.

C. Exemplary Clamping and Firing Sequence

FIGS. 27A-27E show instrument (10) being used to form an anastomosis(70) between two tubular anatomical structures (20, 40). By way ofexample only, the tubular anatomical structures (20, 40) may comprisesections of a patient's esophagus, sections of a patient's colon, othersections of the patient's digestive tract, or any other tubularanatomical structures. As shown in FIG. 27A, anvil (400) is positionedin one tubular anatomical structure (20) and stapling head assembly(300) is positioned in another tubular anatomical structure (40). Inversions where tubular anatomical structures (20, 40) comprise sectionsof a patient's colon, stapling head assembly (300) may be inserted viathe patient's rectum. It should also be understood that the proceduredepicted in FIGS. 27A-27E is an open surgical procedure, though theprocedure may instead be performed laparoscopically. Various suitableways in which instrument (10) may be used to form an anastomosis (70) ina laparoscopic procedure will be apparent to those of ordinary skill inthe art in view of the teachings herein.

As shown in FIG. 27A, anvil (400) is positioned in tubular anatomicalstructure (20) such that shank (420) protrudes from the open severed end(22) of tubular anatomical structure (20). In the present example,purse-string suture (30) is provided about a mid-region of shank (420)to generally secure the position of anvil (400) in tubular anatomicalstructure (20). In some other variations, purse-string suture (30) istightened around the proximal end of shank (420). In some suchvariations, the proximal end of shank (420) may include a notch or otherfeature to securely capture purse-string suture (30). Continuing withthe present example, stapling head assembly (300) is positioned intubular anatomical structure (40) such that trocar (330) protrudes fromthe open severed end (42) of tubular anatomical structure (20). Apurse-string suture (50) is provided about a mid-region of shaft (332)to generally secure the position of stapling head assembly (300) intubular anatomical structure (40). Stapling head assembly (300) is thenurged distally to ensure that stapling head assembly (300) is fullyseated at the distal end of tubular anatomical structure (40).

Next, anvil (400) is secured to trocar (330) by inserting trocar (330)into bore (422) as shown in FIG. 27B. Latch members (430) engage head(334) of trocar (330), thereby providing a secure fit between anvil(400) and trocar (330). The operator then rotates knob (130) whileholding casing (110) stationary via pistol grip (112). This rotation ofknob (130) causes trocar (330) and anvil (400) to retract proximally. Asshown in FIG. 27C, this proximal retraction of trocar (330) and anvil(400) compresses the tissue of tubular anatomical structures (20, 40)between surfaces (412, 322) of anvil (400) and stapling head assembly(300). As this occurs, the operator may observe the tactile resistanceor feedback via knob (130) while turning knob (130), with such tactileresistance or feedback indicating that the tissue is being compressed.As the tissue is being compressed, the operator may visually observe theposition of needle (1526) within user feedback feature (114) todetermine whether the gap distance (d) between opposing surfaces (412,322) of anvil (400) and stapling head assembly (300) is appropriate; andmake any necessary adjustments via knob (130).

Once the operator has appropriately set the gap distance (d) via knob(130), the operator actuates safety trigger (140) (as shown in FIG. 30D)to enable actuation of firing trigger (150). The operator then actuatesfiring trigger (150) (as shown in FIG. 30E). This causes paddle (158) toactuate the switch of a motor activation module (180), therebyactivating motor to rotate cam member (700) (as shown in FIGS. 26A-26D).This rotation of cam member (700) actuates stapling head assembly (300)by driving knife member (340) and staple driver member (350) distally asshown in FIG. 27D. As knife member (340) translates distally, cuttingedge (342) of knife member (340) cuts excess tissue that is positionedwithin annular recess (418) of anvil (400) and the interior of knifemember (340).

As shown in FIG. 4, anvil (400) of the present example includes abreakable washer (417) within annular recess (418). This washer (417) isbroken by knife member (340) when the knife member (340) completes afull distal range of motion from the position shown in FIG. 27C to theposition shown in FIG. 27D. The progressively increasing radius ofcurvature of second surface region may provide an increasing mechanicaladvantage as knife member (340) reaches the end of its distal movement,thereby providing greater force by which to break the washer (417). Ofcourse, the breakable washer (417) may be omitted entirely in someversions. In versions where washer (417) is included, it should beunderstood that washer (417) may also serve as a cutting board for knifemember (340) to assist in cutting of tissue.

As staple driver member (350) translates distally from the positionshown in FIG. 27C to the position shown in FIG. 27D, staple drivermember (350) drives staples (90) through the tissue of tubularanatomical structures (20, 40) and into staple forming pockets (414) ofanvil (400). Staple forming pockets (414) deform the driven staples (90)into a “B” shape as is known in the art; or into a three-dimensionalshape as described above with respect to anvil (500). In either case,the formed staples (90) secure the ends of tissue together.

After the operator has actuated stapling head assembly (300) as shown inFIG. 27D, the operator rotates knob (130) to drive anvil (400) distallyaway from stapling head assembly (300), increasing the gap distance (d)to facilitate release of the tissue between surfaces (412, 322). Theoperator then removes instrument (10) from the patient, with anvil (400)still secured to trocar (330). Referring back to the example where thetubular anatomical structures (20, 40) comprise sections of a patient'scolon, instrument (10) may be removed via the patient's rectum. Withinstrument (10) is removed, the tubular anatomical structures (20, 40)are left secured together by two annular arrays of staples (90) at ananastomosis (70) as shown in FIG. 27E. The inner diameter of theanastomosis (70) is defined by the severed edge (60) left by knifemember (340).

V. Exemplary Safety Assemblies

As noted above, knob (130) may be used to adjust the gap distance (d)between opposing surfaces (412, 322) of anvil (400) and stapling headassembly (300). Setting an appropriate gap distance (d) before actuatingstapling head assembly (300) may be critical to the success of ananastomosis. For instance, if the gap distance (d) is too great, thestaples that are deployed at the anastomosis site may not besufficiently formed by staple forming pockets (414). This may result inleakage at the anastomosis site, and in some cases may ultimately leadto the separation of the anatomical lumen sections that are joined atthe anastomosis site. If the gap distance (d) is too small, the internalstructure of the tissue compressed between surfaces (412, 322) may bedamaged to the point where the structural integrity of the tissue iscompromised. This may prevent the tissue from adequately holding theformed staples, which again may result in leakage or other failure ofthe anastomosis. It may therefore be desirable to provide the operatorwith some form of feedback indicating whether the gap distance (d) iswithin an appropriate range. It may also be desirable to prevent theoperator from actuating stapling head assembly (300) unless the gapdistance (d) is within an appropriate range.

A. Exemplary Trigger Blocking Features and Anvil Position Indicator

FIGS. 28-30E show components that provide feedback to the operator toindicate whether the gap distance (d) is within an appropriate range;and prevent the operator from actuating stapling head assembly (300)unless the gap distance (d) is within an appropriate range. As best seenin FIGS. 30B-30C, a bracket (1500) is configured and positioned to movein response to movement of trocar actuation rod (220). As best seen inFIG. 28, bracket (1500) includes a rigid body (1502) that defines afirst slot (1504), a second slot (1506), and a third slot (1508). Insome variations, third slot (1508) is omitted. An example of such avariation is described below with reference to FIG. 35.

In the present example, an upright member (1510) is positioned at theproximal end of body (1502) and defines an opening (1512). Trocaractuation rod (220) extends coaxially through opening (1512). As shownin FIG. 18, a coil spring (170) is interposed between the proximal endof upright member (1510) and a rigid bulkhead feature that is defined bya chassis (e.g., chassis (3690) described below), which is locatedwithin casing (110). The rigid bulkhead feature forms a support journalfor nut (160). The bulkhead is fixed within the chassis in casing (110)and thereby provides a ground for the proximal end of coil spring (170),such that coil spring (170) resiliently imparts a distal bias to bracket(1500) via upright member (1510). Bracket (1500) further includes alaterally presented flange (1516) at the distal end of body (1502).Flange (1516) defines a slot (1514).

As best seen in FIGS. 30B-30C, an indicator member (1520) is configuredto pivot in response to translation of bracket (1500). As best seen inFIG. 29, indicator member (1520) comprises an upright arm (1522), a snappin (1524) projecting laterally from a lower end of arm (1522), anindicator needle (1526) projecting laterally from an upper end of arm(1522), and a coupling pin (1528) projecting laterally from anintermediate region of arm (1522). Snap pin (1524) is configured to snapinto a complementary recess provided by a chassis (e.g., left chassisportion (3691) of chassis (3690) described below), which is locatedwithin casing (110). Snap pin (1524) thereby secures indicator member(1520) to the chassis yet permits indicator member (1520) to pivotrelative to the chassis about the longitudinal axis of snap pin (1524).Indicator needle (1526) is positioned to be visible through userfeedback feature (114) of handle assembly (100) to thereby visuallyindicate the pivotal position of indicator member (1520). Coupling pin(1528) is slidably received in slot (1514) of flange (1516) of bracket(1500). This engagement between indicator member (1520), the chassis incasing (110), and bracket (1500) provides pivotal movement of indicatormember (1520) in response to translation of bracket (1500).

Bracket (1500) is configured to selectively prevent and permit actuationof triggers (140, 150). In particular, slots (1504, 1506) of bracket(1500) are configured to selectively provide clearance for actuation oftriggers (140, 150). As shown in FIGS. 30A-30E, safety trigger (140) ispivotably coupled with a first upright member (144). First uprightmember (144) is coupled with a chassis (e.g., chassis (3690) describedbelow), which is located within casing (110), such that first uprightmember (144) is configured to translate upwardly in response to pivotingof safety trigger (140) toward pistol grip (112). However, body (1502)of bracket (1500) is configured to prevent this movement of firstupright member (144) and safety trigger (140) by engaging the upper end(146) of first upright member (144). Body (1502) thus blocks movement offirst upright member (144) and safety trigger (140) until bracket (1500)is moved to a position where slot (1506) is aligned with upper end (146)to thereby provide clearance for upward movement of first upright member(144). It should therefore be understood that safety trigger (140)cannot be pivoted toward pistol grip (112) until slot (1506) ispositioned over upper end (146).

Similarly, firing trigger (150) is pivotably coupled with a secondupright member (154). Second upright member (154) is coupled with achassis (e.g., chassis (3690) described below), which is located withincasing (110), such that second upright member (154) is configured totranslate upwardly in response to pivoting of firing trigger (150)toward pistol grip (112). However, body (1502) of bracket (1500) isconfigured to prevent this movement of second upright member (154) andfiring trigger (150) by engaging the upper end (156) of second uprightmember (154). Even if safety trigger (140) is pivoted out of the way tootherwise permit movement of firing trigger (150), body (1502) blocksmovement of second upright member (154) and firing trigger (150) untilbracket (1500) is moved to a position where slot (1504) is aligned withupper end (156) to thereby provide clearance for upward movement ofsecond upright member (154). It should therefore be understood that,even if safety trigger (140) is pivoted out of the way to otherwisepermit movement of firing trigger (150), firing trigger (150) cannot bepivoted toward pistol grip (112) until slot (1504) is positioned overupper end (156).

Third slot (1508) is configured to receive a downwardly projecting boss(223) of clip (222), which is rigidly secured to trocar actuation rod(220). While a chassis (e.g., chassis (3690) described below), which islocated within casing (110), is configured to allow bracket (1500) totranslate longitudinally relative to the chassis, the chassis includesrails, channels, and/or other features that prevent bracket (1500) fromrotating relative to the chassis. Thus, the positioning of boss (223) inslot (1508) prevents clip (222) and trocar actuation rod (220) fromrotating relative to the chassis. Boss (223) and slot (1508)nevertheless allow bracket (1500) to translate longitudinally withincasing (110) as will be described in greater detail below. As notedherein, third slot (1508) is merely optional and may be omitted in someversions.

FIGS. 30A-30E depict the above-described components at various stages ofoperation. In particular, in FIG. 30A, trocar actuation rod (220) is ina distal-most position, such that trocar (330) is in a distal-mostposition. At this stage, the operator may couple anvil (400) with trocar(330) by inserting trocar (330) into bore (422) until latch members(430) are secured to head (334) of trocar (330). The operator thenrotates knob (130), which rotates nut (160). As knob (130) and nut (160)rotate, engagement between coarse helical threading (224) of trocaractuation rod (220) and the complementary feature of nut (160) causestrocar actuation rod (220) to retract proximally at a relatively rapidrate, such that trocar actuation rod (220) reaches the position shown inFIG. 30B. This provides proximal retraction of trocar actuation rod(220) provides retraction of trocar (330) and anvil (400). As trocaractuation rod (220) moves from the position shown in FIG. 30A to theposition shown in FIG. 30B, bracket (1500) remains stationary. This isdue to the fact that clip (222) is spaced apart from upright member(1510) at the stage shown in FIG. 30A and does not engage upright member(1510) until trocar actuation rod (220) reaches the position shown inFIG. 30B.

After reaching the stage shown in FIG. 30B, the operator may continuerotating knob (130) and nut (160), which causes further proximalretraction of trocar actuation rod (220) as shown in FIG. 30C. This ofcourse causes further proximal retraction of trocar (330) and anvil(400). As trocar actuation rod (220) moves from the position shown inFIG. 30B to the position shown in FIG. 30C, clip (222) bears againstbracket (1500), driving bracket (1500) proximally. This proximalmovement of bracket (1500) causes indicator member (1520) to pivot fromthe position shown in FIG. 30B to the position shown in FIG. 30C due tothe positioning of coupling pin (1528) in slot (1514) of flange (1516).

As indicator member (1520) pivots from the position shown in FIG. 30B tothe position shown in FIG. 30C, the operator may observe the position ofindicator needle (1526) through user feedback feature (114) of handleassembly (100). As described in greater detail below, a series of hashmarks, colored regions, and/or other fixed indicators may be positionedadjacent to user feedback feature (114) in order to provide a visualcontext for indicator needle (1526), thereby facilitating operatorevaluation of the position of needle (1526) within user feedback feature(114). It should be understood that the position of needle (1526) withinuser feedback feature (114) will be indicative of the longitudinalposition of trocar (330) and anvil (400). The position of needle (1526)within user feedback feature (114) will thus indicate the gap distance(d) between opposing surfaces (412, 322) of anvil (400) and staplinghead assembly (300). While observing the position of needle (1526)within user feedback feature (114), the operator may rotate knob (130)clockwise or counterclockwise to further retract or advance trocar (330)and anvil (400), thereby providing fine adjustment of the gap distance(d) until a desired gap distance (d) is reached within an appropriaterange.

In order to provide fine control of the gap distance (d) adjustment atthe stage shown in FIG. 30C, trocar actuation rod (220) will be at alongitudinal position where fine helical threading (226) is engaged witha complementary feature of knob (130) and coarse helical threading (224)is disengaged from the complementary feature of nut (160). In someversions, coarse helical threading (224) disengages nut (160) and finehelical threading (226) begins to engage knob (130) once trocaractuation rod (220) reaches the longitudinal position shown in FIG. 30B(i.e., when clip (222) first engages upright member (1510)). In someother versions, the transition from engagement by coarse helicalthreading (224) to fine helical threading (226) occurs sometime betweenthe stage shown in FIG. 30B and the stage shown in FIG. 30C. Othersuitable stages at which the coarse-to-fine transition may occur will beapparent to those of ordinary skill in the art in view of the teachingsherein. It should also be understood that some alternative versions oftrocar actuation rod (220) may have just a single threading section,with the pitch of the threading being consistent along the length of thethreading. In other words, trocar actuation rod (220) does notnecessarily need to have two different sections of threading (224, 226)with different pitches.

At the stage shown in FIG. 30C, slot (1506) is aligned with upper end(146) to thereby provide clearance for upward movement of first uprightmember (144). Similarly, slot (1504) is aligned with upper end (156) tothereby provide clearance for upward movement of second upright member(154). In the present example, slots (1504, 1506) are sized andpositioned such that slots (1504, 1506) only provide clearance forupward movement of upright members (144, 154) when the gap distance (d)is within a clinically acceptable range. By way of example only, a“clinically acceptable range” for the gap distance (d) may be betweenapproximately 0.110 inches and approximately 0.040 inches. As anothermerely illustrative example, a “clinically acceptable range” for the gapdistance (d) may be between approximately 0.110 inches and approximately0.020 inches. Even when slots (1504, 1506) are positioned to provideclearance for upward movement of upright members (144, 154) as shown inFIG. 30C, safety trigger (140) will still block pivotal movement offiring trigger (150) about a pin (152) (FIG. 9) when safety trigger(140) is in the non-actuated position shown in FIG. 30C. Thus, in orderto enable movement of firing trigger (150), the operator will need tofirst actuate safety trigger (140) about a pin (142) (FIG. 9) from theposition shown in FIG. 30C to the position shown in FIG. 30D.

As shown in FIG. 30D, upper end (146) passes through slot (1506) assafety trigger (140) is pivoted from the position shown in FIG. 30C tothe position shown in FIG. 30D. It should be understood that thismovement of upper end (146) would not be possible at the stages shown inFIGS. 30A-30B (when the gap distance (d) is too great) because body(1502) would physically block upward movement of upright member (144),thereby physically blocking pivotal movement of safety trigger (140). Inthe present example, a cap (not shown) incorporated into knob (130)prevents knob (130) from rotating to a point where anvil (400) would beretracted too far proximally (such that the gap distance (d) is toosmall). In some other variations, even if knob (130) were to permitanvil (400) to be retracted too far proximally (such that the gapdistance (d) is too small), body (1502) would physically block upwardmovement of upright member (144), thereby physically blocking pivotalmovement of safety trigger (140), in the event that the operatorretracts trocar (330) and anvil (400) too far proximally (such that thegap distance (d) is too small). Regardless of whether body (1502), knob(130), or some other feature prevents actuation when the gap distance(d) would be too small, it should be understood that instrument (10)permits actuation of safety trigger (140) only when the gap distance (d)is within the clinically acceptable range.

As noted above, safety trigger (140) is configured to prevent actuationof firing trigger (150) until safety trigger (140) has been actuated.Once safety trigger (140) has been actuated, the operator may actuatefiring trigger (150) from the position shown in FIG. 30D to the positionshown in FIG. 30E. As shown in FIG. 30E, upper end (156) passes throughslot (1504) as firing trigger (150) is pivoted from the position shownin FIG. 30D to the position shown in FIG. 30E. It should be understoodthat, even in the complete absence of safety trigger (140), thismovement of upper end (156) would not be possible at the stages shown inFIGS. 30A-30B (when the gap distance (d) is too great) because body(1502) would physically block upward movement of upright member (154),thereby physically blocking pivotal movement of firing trigger (150).Thus, even in the complete absence of safety trigger (140), firingtrigger (150) may only be actuated when the gap distance (d) is withinthe clinically acceptable range.

Firing trigger (150) of the present example includes integral actuationpaddle (158). Paddle (158) pivots forwardly as firing trigger (150)pivots from the position shown in FIG. 30D to the position shown in FIG.30E. Paddle (158) is configured to actuate a switch of a motoractivation module (180), which is shown in FIG. 9, when firing trigger(150) pivots from the position shown in FIG. 30D to the position shownin FIG. 30E. Motor activation module (180) is in communication withbattery pack (120) and motor (161), such that motor activation module(180) is configured to provide activation of motor (161) with electricalpower from battery pack (120) in response to paddle (158) actuating theswitch of motor activation module (180). Thus, motor (161) will beactivated when firing trigger (150) is pivoted from the position shownin FIG. 30D to the position shown in FIG. 30E. This activation of motor(161) will actuate stapling head assembly (300) as described in greaterdetail below.

As shown in FIG. 31, safety trigger (140) of the present exampleincludes a laterally extending detent protrusion (141). Protrusion (141)is configured to cooperate with a corresponding detent recess (notshown) of a portion of a chassis (e.g., chassis (3690) described below),to selectively retain safety trigger (140) in the flipped-up positionshown in FIGS. 30D-30E. In other words, protrusion (141) is configuredto prevent inadvertent movement of safety trigger (140) from theflipped-up position (FIGS. 30D-30E) to the flipped-down position (FIGS.30A-30C). Protrusion (141) nevertheless enables an operator tointentionally transition safety trigger (140) between the flipped-upposition (FIGS. 30D-30E) and the flipped-down position (FIGS. 30A-30C).

As also shown in FIG. 31, first upright member (144) defines a lateralnotch (148) below upper end (146) of first upright member (144). Lateralnotch (148) is configured to provide clearance for longitudinal movementof bracket (1500) after safety trigger (140) is in the flipped-upposition (FIGS. 30D-30E), where first upright member (144) is in anupper position. For instance, if an operator achieves a firstlongitudinal position of anvil (400) and trocar (330) where anvil (400)is in the “green zone” as described herein, then the operator actuatessafety trigger (140) to the flipped-up position, then the operatormanipulates knob (130) again to reposition anvil (400), bracket (1500)will translate during this repositioning of anvil (400). In the eventthat the operator repositions anvil (400) out of the “green zone,”bracket (1500) will be at a longitudinal position where slot (1506) isno longer aligned with upper end (146) of first upright member (144).Thus, first upright member (144) will not be sheared or otherwisedamaged in the event that the operator repositions anvil (400) out ofthe “green zone” after actuating safety trigger (140) to the flipped-upposition. If anvil (400) is moved out of the “green zone” after safetytrigger (140) is actuated to the flipped-up position, bracket (1500)will still prevent firing trigger (150) from being actuated since slot(1504) is not aligned with upper end (156) of second upright member(154) when anvil (400) is outside of the “green zone.”

B. Exemplary User Interface Feature

As noted above, as indicator member (1520) pivots from the positionshown in FIG. 30B to the position shown in FIG. 30C, the operator mayobserve the position of indicator needle (1526) in user feedback feature(114) of handle assembly (100). In particular, and as best seen in FIG.32, user feedback feature (114) of the present example (also referred toherein as a “user interface”) includes a graphical indicator (3550)(also referred to herein as a “lens member”), which includes fixedlinear indicia (3552, 3554, 3556), graphical representations (3560,3562) of staples, and a checkmark feature (3564). User feedback feature(114) further defines a window (3570) through which indicator needle(1526) may be viewed. In some variations, user feedback feature (114)further includes a field (3566) that may indicate a diameter associatedwith the size of stapling head assembly (300), the size of staples instapling head assembly (300), the size of the gap defined between anvil(400) and stapling head assembly (300), and/or other information. By wayof example only, field (3566) may indicate a stapling head assembly(300) size of 23 mm, 25 mm, 29 mm, or 31 mm.

As the operator rotates knob (130) to adjust the longitudinal positionof anvil (400) relative to stapling head assembly (300), the operatormay observe the position of indicator needle (1526) through window(3570), such that window (3570) and indicator needle (1526) cooperate todefine a user feedback element of user feedback feature (114).Initially, indicator needle (1526) may be positioned at or near thedistal end of window (3570). As anvil (400) continues to moveproximally, indicator needle (1526) will eventually move proximallyrelative to window (3570). The operator may view the position ofindicator needle (1526) in relation to fixed linear indicia (3552, 3554,3556). The distal-most and proximal-most indicia (3552, 3556) mayrepresent the boundaries of a “green zone,” which is the acceptablerange of distance between anvil (400) and stapling head assembly (300)for successful actuation of stapling head assembly (300). Thus, ifindicator needle (1526) is distal to distal-most indicia (3552), thedistance between anvil (400) and stapling head assembly (300) is toolarge; and if indicator needle (1526) is proximal to proximal-mostindicia (3556), the distance between anvil (400) and stapling headassembly (300) is too small. Indicia (3554) is longitudinally positionedbetween indicia (3552, 3556). Graphical representation (3560) representsa relatively tall formed staple (e.g., suitable for use in relativelythick tissue); while graphical representation (3562) represents arelatively short formed staple (e.g., suitable for use in relativelythin tissue). Graphical representations (3560, 3562) may thus facilitatethe operator's decision, based on tissue observations or otherwise, onwhether and how to achieve a desired formed staple height by selectingan appropriate corresponding spatial relationship between indicatorneedle (1526) and indicia (3552, 3554, 3556).

In the present example, window (3570) is illuminated via a first lightsource (2702) in the form of a first light emitting diode (LED) (seeFIG. 83), further facilitating viewing of indicator needle (1526) inwindow (3570). In addition, checkmark feature (3564) is illuminated viaa second light source (2704) in the form of a second LED (see FIG. 83)when stapling head assembly (300) completes a stapling and cuttingcycle. Thus, the operator may further rely on illumination of checkmarkfeature (3564) to confirm that the stapling and cutting cycle iscomplete, to thereby verify that it is safe to advance anvil (400)distally away from the anastomosis (70) and remove instrument (10) fromthe patient. In this capacity, checkmark feature (3564) functions asanother user feedback element of user feedback feature (114). By way ofexample only, LED (2702) associated with window (3570) may be configuredto emit white visible light while LED (2704) associated with checkmarkfeature (3564) may be configured to emit green visible light. In someversions, control circuit (2700) is configured to provide illuminationof the LED (2702) associated with window (3570) as soon as battery pack(120) is inserted into casing (110). It will be appreciated that inother versions of instrument (10), one or both of first and second lightsources (2702, 2704) may take various other suitable forms other than anLED.

C. Exemplary Hysteresis Avoidance Features

As noted above, indicator member (1520) and user feedback feature (114)cooperate to provide the operator with visual feedback indicating thelongitudinal position of anvil (400) relative to stapling head assembly(300). Those of ordinary skill in the art will recognize that theprecision of this positioning may be critical to the successfulformation of an anastomosis (70). Thus, the real-time accuracy of thefeedback provided by indicator member (1520) and user feedback feature(114) may be critical to the successful formation of an anastomosis(70).

Some versions of bracket (1500) and indicator member (1520) may providesome degree of hysteresis, such that there is a slight lag time betweenthe adjustment of the longitudinal position of anvil (400) relative tostapling head assembly (300) and the position of indicator member (1520)in user feedback feature (114). This hysteresis may be attributable tomanufacturing tolerances and/or other factors. This hysteresis maycompromise the real-time accuracy of the feedback provided by indicatormember (1520) and user feedback feature (114), which may in turncompromise the success of the anastomosis (70). It may therefore bedesirable to configure bracket (1500), indicator member (1520), andassociated features to eliminate or at least minimize such hysteresis,to thereby promote greater real-time accuracy of the feedback providedby indicator member (1520) and user feedback feature (114), to in turnthereby promote a greater chance of success in the formation of ananastomosis (70).

FIGS. 33-39D show exemplary alternative features that may beincorporated into instrument (10) to promote greater real-time accuracyof visual feedback indicating the longitudinal position of trocar (330)and anvil (400) relative to stapling head assembly. In particular, FIGS.33-34 show an exemplary alternative indicator member (3600) that may beused in place of indicator member (1520); while FIG. 35 shows anexemplary alternative bracket (3650) that may be used in place ofbracket (1500).

As shown in FIGS. 33-34, indicator member (3600) of this examplecomprises an upright arm (3604), a snap pin (3602) projecting laterallyfrom a lower end of arm (3604), an indicator needle (3606) projectinglaterally from an upper end of arm (3604), and a coupling pin (3608)projecting laterally from an intermediate region of arm (3604). Snap pin(3602) is configured to snap into a complementary recess provided by aportion of a chassis (3690) as described below. Indicator needle (3606)is positioned to be visible in user feedback feature (114) of handleassembly (100), as described above with respect to indicator needle(1526), to thereby visually indicate the pivotal position of indicatormember (3600), which will indicate the longitudinal position of anvil(400) relative to stapling head assembly (300). Coupling pin (3608) isconfigured to fit in an opening (3672) of a flange (3670) of bracket(3650), as described below. As also described below, this engagementbetween indicator member (3600), chassis (3690), and bracket (3650)provides pivotal movement of indicator member (3600) in response totranslation of bracket (3650). Unlike indicator member (1520) describedabove, indicator member (3600) of the present example comprises aresilient arm (3610), which projects upwardly and is resiliently biasedto define an oblique angle relative to upright arm (3604). As describedin greater detail below, resilient arm (3610) is configured to interactwith chassis (3690) to provide a resilient angular bias to indicatormember (3600).

As shown in FIG. 35, bracket (3650) of this example comprises a rigidbody (3656) that defines a first slot (3660) (which is analogous tofirst slot (1504), described above) and a second slot (3658) (which isanalogous to second slot (1506), described above). An upright member(3652) (which is analogous to upright member (1510), described above) ispositioned at the proximal end of body (3656) and defines an opening(7204) (which is analogous to opening (1512), described above). Opening(7204) is sized to receive trocar actuation rod (220); and uprightmember (3652) is configured to engage coil spring (170), just like theanalogous features of bracket (1500) described above. Bracket (3650)further includes a laterally presented flange (3670), which defines anopening (3672). Opening (3672) extends between a distal edge (3674) anda proximal edge (3676). Bracket (3650) includes a proximal portion and adistal portion

As shown in FIG. 36, and as noted above, pin (3608) is configured to fitin opening (3672) of flange (3670). The width of opening (3672) islarger than the width of pin (3608), such that pin (3608) cannot contactboth edges (3674, 3676) simultaneously. This structural relationshipbetween the width of opening (3672) and the width of pin (3608) providessome degree of lost motion between bracket (3650) and indicator member(3600), as described below with reference to FIGS. 39A-39D.

FIG. 37 shows an exemplary left chassis portion (3691) of chassis (3690)that may be incorporated into handle assembly (100). Chassis (3690) isconfigured to provide a mechanical ground relative to movable componentsof handle assembly (100). Left chassis portion (3691) of chassis (3690)of this example comprises a distally presented ridge (3692) that ispositioned for engagement with resilient arm (3610) of indicator member(3600). As shown in FIG. 37, snap pin (3602) is configured to beinserted into chassis (3690). Snap pin (3602) thereby secures indicatormember (3600) to chassis (3690) yet permits indicator member (3600) topivot relative to chassis (3690) about the longitudinal axis of snap pin(3602).

FIGS. 38A-38D show various angular positions of indicator member (3600)relative to chassis (3690) as trocar (330) and anvil (400) are retractedproximally relative to stapling head assembly (300). In particular, FIG.38A shows indicator member (3600) at a first angular orientation. Thisfirst angular orientation would be associated with trocar (330) andanvil (400) being at a furthest distal position relative to staplinghead assembly (300). For instance, this orientation may be associatedwith the operational states depicted in FIGS. 30A and 27B. Withindicator member (3600) at this first angular orientation, resilient arm(3610) is not in contact with ridge (3692) of chassis (3690), such thata gap is defined between resilient arm (3610) and ridge (3692).

As the operator rotates knob (130) to retract trocar (330) and anvil(400) proximally relative to stapling head assembly (300), bracket(3650) eventually pulls pin (3608) proximally, thereby causing indicatormember (3600) to pivot clockwise (in the view shown in FIGS. 38A-38D)relative to chassis (3690). During this clockwise pivotal movement,resilient arm (3610) eventually contacts ridge (3692) of chassis (3690),as shown in FIG. 38B. During the stages shown in FIGS. 38A and 38B,resilient arm (3610) is in a non-stressed state. However, as theoperator continues to rotate knob (130) to retract trocar (330) andanvil (400) further proximally relative to stapling head assembly (300),bracket (3650) continues to pull pin (3608) proximally, thereby causingindicator member (3600) to pivot clockwise further relative to chassis(3690). This results in deformation of resilient arm (3610), as shown inFIG. 38C. In the present example, resilient arm (3610) contacts ridge(3692) and starts deforming before anvil (400) reaches the “green zone”referred to above.

With resilient arm (3610) deformed as shown in FIG. 38C, resilient arm(3610) is in a stressed state, such that indicator member (3600) isresiliently biased in the counterclockwise (in the view shown in FIGS.38A-38D) direction. Despite the stressed state of resilient arm (3610),the operator may continue to rotate knob (130) to retract trocar (330)and anvil (400) further proximally relative to stapling head assembly(300), thereby causing indicator member (3600) to pivot clockwisefurther relative to chassis (3690), eventually reaching the state shownin FIG. 38D. At this stage, resilient arm (3610) may engage upright arm(3604), such that resilient arm (3610) may not deform further. In someversions, bracket (3650) may not be enabled to translate proximally farenough for resilient arm (3610) to ground out against upright arm(3604). When the operator reverses rotation of knob (130) to therebyadvance anvil (400) distally while resilient arm (3610) is in a stressedstate, resilient arm (3610) will drive indicator member (3600) to rotatecounterclockwise.

As noted above, the structural relationship between the width of opening(3672) and the width of pin (3608) provides some degree of lost motionbetween bracket (3650) and indicator member (3600). This lost motion isshown in FIGS. 39A-39B. FIG. 39A shows bracket (3650) in a distal-mostposition. This operational state corresponds with the operational stateshown in FIG. 38A. At this stage, proximal edge (3676) of opening (3672)is engaged with pin (3608); and pin (3608) is spaced apart from distaledge (3674) of opening (3672).

As bracket (3650) translates proximally with trocar (330) and anvil(400), bracket (3650) eventually reaches the longitudinal position shownin FIG. 39B. At this stage, distal edge (3674) of opening (3672) isengaged with pin (3608); and pin (3608) is spaced apart from proximaledge (3676) of opening (3672). However, during the transition from thestage shown in FIG. 39A to the stage shown in FIG. 39B, indicator member(3600) has not pivoted. Indicator member (3600) has thus remainedstationary while bracket (3650) has translated from the position shownin FIG. 39A to the position shown in FIG. 39B. In the context of thestages shown in FIGS. 38A-38D, indicator member (3600) would remain inthe position shown in FIG. 38A during the stage shown in FIG. 39A andthe stage shown in FIG. 39B. In the present example, opening (3672) issized and configured such that pin (3608) will engage distal edge (3674)of opening (3672) as shown in FIG. 39B before anvil (400) has reached adistance associated with the “green zone” as described above. Moreover,resilient arm (3610) will contact ridge (3692) before anvil (400) hasreached a distance associated with the “green zone” as described above.Thus, indicator needle (3606) will not be positioned proximal todistal-most indicia (3552) in user feedback feature (114) until afterindicator member (3600) has reached the position shown in FIG. 38B,which will not occur until after bracket (3650) has reached the positionshown in FIG. 39B.

As bracket (3650) continues to translate proximally with trocar (330)and anvil (400), bracket (3650) eventually reaches the longitudinalposition shown in FIG. 39C. During the range of movement between thestage shown in FIG. 39B and the stage shown in FIG. 39C, At this stage,distal edge (3674) of flange (3670) bears against pin (3608) to drivepin (3608) proximally, thereby indicator member (3600) to the positionshown in FIG. 39C. While chassis (3690) is omitted from FIGS. 39A-39D,those of ordinary skill in the art will recognize that resilient arm(3610) will be deformed (and thereby stressed) due to engagement betweenresilient arm (3610) and ridge (3692) during the transition from thestage shown in FIG. 39B and the stage shown in FIG. 39C. Those ofordinary skill in the art will also recognize that the relationshipbetween bracket (3650) and indicator member (3600) shown in FIG. 39Cwill be provided throughout the range of motion associated withtransitioning among the stages shown in FIGS. 38B-38D.

As noted above, after anastomosis (70) has been formed, or while theoperator is adjusting the gap distance (d) between anvil (400) andstapling head assembly (300), the operator may drive trocar (330) andanvil (400) distally. When this occurs, bracket (3650) will alsotranslate distally. This will result in movement shown in FIG. 39D.Since bracket (3650) is already in a proximal position (e.g., theposition shown in FIG. 39C) before such distal movement is initiated,resilient arm (3610) is in a stressed state, thereby urging indicatormember (3600) to pivot distally. Due to this resilient bias, pin (3608)remains engaged with distal edge (3674) of opening (3672) as bracket(3650) moves distally. As the operator continues to rotate knob (130) todrive trocar (330) and anvil (400) distally, the distally translatingbracket (3650) allows resilient arm (3610) to drive indicator member(3600) back toward the pivotal position shown in FIGS. 39A-39B. Afterindicator member (3600) reaches the pivotal position shown in FIGS.39A-39B, distal edge (3674) disengages pin (3608) and bracket (3650) maycontinue to translate distally through a certain range of motion beforereaching the longitudinal position shown in FIG. 39A.

In the present example, the lost motion between bracket (3650) andindicator (3600) between the stage shown in FIG. 39A and the stage shownin FIG. 39B, and the lost motion between resilient arm (3610) and ridge(3692) between the stage shown in FIG. 38A and the stage shown in FIG.38B, remove hysteresis from movement of indicator arm (3600) as trocar(330) and anvil (400) are retracted proximally toward stapling headassembly (300). Likewise, the lost motion between bracket (3650) andindicator (3600) between the stage shown in FIG. 39B and the stage shownin FIG. 39A, and the lost motion between resilient arm (3610) and ridge(3692) between the stage shown in FIG. 38B and the stage shown in FIG.38A, remove hysteresis from movement of indicator arm (3600) as trocar(330) and anvil (400) are advanced distally away from stapling headassembly (300). During advancement and retraction, this lost motion willoccur when anvil (400) is outside of the “green zone” referred to above.Thus, the lost motion will reduce the likelihood that the operator ismisled into thinking that anvil (400) is in the “green zone” due tohysteresis that might otherwise keep indicator needle (3606) betweenindicia (3552, 3556) when anvil (400) is in fact outside of the “greenzone.”

VI. Exemplary Operational Routines

While the sequence described above with reference to FIGS. 27A-27Erelates to how instrument (10) may be used by an operator in a surgicalprocedure, it should be understood that there are various routines thatmay be performed within instrument (10) before, during, and after theprocedure depicted in FIGS. 27A-27E. FIGS. 40A-40B show various steps inan exemplary process (4000) that may be carried out through instrument(10) before, during, and after the procedure depicted in FIGS. 27A-27E.It should be understood that various steps of process (4000) are merelyoptional and may be omitted if desired.

In the present example, process (4000) begins with an operator insertingbattery pack (120) into socket (116) of handle assembly (100), as shownin block (4002). In some versions, the insertion of battery pack (120)into socket (116) will automatically trigger one or more additionalsteps in process (4000). For instance, as shown in block (4004), theinsertion of battery pack (120) into socket (116) may automaticallyactivate a drain switch that begins to drain power from battery pack(120) once battery pack (120) is removed from casing (110). By way ofexample only, such automatic drainage of power from battery pack (120)may be provided in accordance with at least some of the other teachingsherein. In addition or in the alternative, automatic drainage of powerfrom battery pack (120) may be provided in accordance with at least someof the teachings below. Other suitable ways in which power may beautomatically drained from battery pack (120) upon insertion of batterypack (120) into socket (116) will be apparent to those of ordinary skillin the art in view of the teachings herein. Alternatively, in someversions the step shown in block (4004) is simply omitted.

In addition to or as an alternative to automatically initiating drainageof power from battery pack (120), the insertion of battery pack (120)into socket (116) may also mechanically unlock the ability to retracttrocar (330) and anvil (400) proximally, as shown in block (4006). Byway of example only, such unlocking of the ability to retract trocar(330) and anvil (400) proximally may be provided in accordance with atleast some of the other teachings herein. Other suitable ways in whichthe ability to retract trocar (330) and anvil (400) proximally may beautomatically unlocked upon insertion of battery pack (120) into socket(116) will be apparent to those of ordinary skill in the art in view ofthe teachings herein. Alternatively, in some versions the step shown inblock (4006) is simply omitted.

It should also be understood that the insertion of battery pack (120)into socket (116) may provide a necessary electrical connection withinthe circuit that actuates stapling head assembly (300), as shown inblock (4008). In other words, in the absence of battery pack (120), thecircuit that actuates stapling head assembly will lack a necessaryelectrical connection. In some other versions, instrument (10) iscapable of receiving electrical power from some other source, such thatbattery pack (120) need not necessarily be inserted into socket (116) inorder to complete a circuit that is operable to actuate stapling headassembly (300).

In some versions, the insertion of battery pack (120) into socket (116)may also mechanically unlock the ability to actuate safety trigger(140), as shown in block (4010). Various suitable ways in which theinsertion of battery pack (120) into socket (116) may mechanicallyunlock the ability to actuate safety trigger (140) will be apparent tothose of ordinary skill in the art in view of the teachings herein.Alternatively, in some versions the step shown in block (4010) is simplyomitted.

Regardless of whether (or the extent to which) the steps shown in blocks(4004, 4006, 4008, 4010) are ultimately included in process (4000),process (4000) may proceed with insertion of anvil (400) into anatomicalstructure (20), as shown in block (4012). This step is also shown inFIG. 27A as discussed above. Continuing on with process (4000) as shownin FIGS. 40A-40B, anvil (400) is then secured to trocar (330) as shownin block (4014). This step is also shown in FIG. 27B as discussed above.Continuing on with process (4000) as shown in FIGS. 40A-40B, anvil (400)and trocar (330) are then retracted proximally to compress the tissue ofanatomical structures (20, 40), as shown in block (4016). This step isalso shown in FIG. 27C as discussed above. The operator rotates knob(130) in order to achieve an appropriate gap distance (d), as shown inblock (4018). This step is also shown in FIGS. 30B-30C and 27C asdiscussed above.

In some instances, instrument (10) includes electromechanical featuresthat monitor the gap distance (d) and provide feedback to the operatorrelating to the gap distance (d). By way of example only, such featuresmay be provided in accordance with at least some of the other teachingsherein. Other suitable ways in which an instrument (10) may monitor thegap distance (d) and provide feedback to the operator relating to thegap distance (d) will be apparent to those of ordinary skill in the artin view of the teachings herein. For those versions of instrument (10)that do have this capability, process (4000) includes such monitoring ofthe gap distance (d) as shown in block (4020). In some other versions,the step shown in block (4020) is omitted. Instrument (10) may provideaudible, visual, and or tactile feedback relating to the gap distance(d) as shown in block (4022). In the event that the gap distance (d)falls below the clinically acceptable range (i.e., anvil (400) isgetting too close to stapling head assembly (300)), instrument (10) mayprovide an indication to the operator to indicate that anvil (400) needsto be advanced distally to increase the gap distance (d), as shown inblock (4024). In some other versions, the step shown in block (4024) isomitted. Thus, some versions may lack electromechanical features thatmonitor the gap distance (d) and provide feedback to the operatorrelating to the gap distance (d). In some such versions, purelymechanical features (e.g., indicator needle (3606), etc.) may be used tomonitor the gap distance (d) and provide feedback to the operatorrelating to the gap distance (d).

Regardless of whether instrument (10) includes electromechanicalfeatures that monitor the gap distance (d) and provide feedback to theoperator relating to the gap distance (d), bracket (1500) will move to aposition where it unblocks actuation of safety trigger (140) when thegap distance (d) reaches the clinically acceptable range, as shown inblock (4026). Such positioning of bracket (1500) is also shown in FIG.30C as described above. The operator may actuate safety trigger (140)once bracket (1500) has moved into the unblocking position, as shown inblock (4028). Such actuation of safety trigger (140) is also shown inFIG. 30D as described above. Once safety trigger (140) has beenactuated, the operator may then actuate firing trigger (150), as shownin block (4030). Such actuation of firing trigger (150) is also shown inFIG. 30E as described above.

Once the operator actuates firing trigger (150), instrument (10) willcomplete an actuation stroke of stapling head assembly (300), regardlessof what the operator does next with firing trigger (150), as shown inblock (4032). In other words, the assembly that actuates stapling headassembly (300) (i.e., motor (161) and the rest of the components thatcouple motor (161) with stapling head assembly (300)) will effectivelybe fully committed to actuating stapling head assembly (300) once theoperator actuates firing trigger (150), even if the operator furthermanipulates firing trigger (150). By way of example only, instrument(10) may include components that provide full commitment to theactuation of stapling head assembly (300) in response to actuation offiring trigger (150) in accordance with at least some of the teachingsof U.S. Pat. No. 9,907,552, entitled “Control Features for MotorizedSurgical Stapling Instrument,” issued Mar. 6, 2018, the disclosure ofwhich is incorporated by reference herein. Alternatively, instrument(10) may include components that provide full commitment to theactuation of stapling head assembly (300) in response to actuation offiring trigger (150) in accordance with the teachings below.

The actuation stroke of stapling head assembly (300) includes the distaland proximal motion of various components, as shown in block (4034).This alternating motion is shown in FIGS. 24A-24B and in FIGS. 26A-26Das described above. The distal motion is also shown in FIG. 27D asdescribed above.

In some versions of instrument (10), while the firing mechanismcompletes the actuation stroke of stapling head assembly (300),instrument (10) may include features that detect strain within thefiring mechanism as shown in block (4036). By way of example only, suchsensing may be provided in accordance with at least some of the otherteachings herein. Other suitable ways in which instrument (10) mayincorporate features that sense strain in the firing system be apparentto those of ordinary skill in the art in view of the teachings herein.Alternatively, such features may be omitted such that the step shown inblock (4036) is omitted. In the event that such features are included,instrument (10) may provide an audible, visual, and/or tactileindication in the event that the sensing feature(s) detected that thestrain has exceeded a threshold, as shown in block (4038). Of course,the step shown in block (4038) may be omitted in some versions.

In addition to or as an alternative to features that detect strain inthe firing mechanism during the actuation stroke of stapling headassembly (300), some versions of instrument (10) may include a switch orother kind of sensor that detects whether a portion of the firingmechanism has traveled to an expected distance during the actuationstroke, as indicated in block (4040). By way of example only, suchsensing may be provided in accordance with at least some of the otherteachings herein. Other suitable ways in which instrument (10) mayincorporate features that sense whether the firing mechanism hascompleted sufficient travel will be apparent to those of ordinary skillin the art in view of the teachings herein. Alternatively, such featuresmay be omitted such that the step shown in block (4040) is omitted. Inthe event that such features are included, instrument (10) may providean audible, visual, and/or tactile indication in the event that thesensing feature(s) detected that the actuation stroke of stapling headassembly (300) was successfully completed, as shown in block (4042).

Once stapling head assembly (300) has been successfully actuated, anvil(400) may be advanced distally from stapling head assembly (300) andinstrument (10) may be withdrawn from the patient, as shown in block(4044). After instrument (10) has been withdrawn from the patient, theoperator may remove battery pack (120) from handle assembly (100), asshown in block (4046).

As noted above, the above-described steps of process (4000) are merelyillustrative examples. Instrument (10) may be used in various other waysas will be apparent to those of ordinary skill in the art in view of theteachings herein. In addition, instrument (10) may have various otherfunctionalities as will be apparent to those of ordinary skill in theart in view of the teachings herein. It should be understood that somevariations of instrument (10) may be incapable of performing some of thesteps of process (4000). Moreover, some versions of instruments (10) maybe capable of performing steps that are not included in process (4000).

As noted above with reference to block (4032), it may be desirable toensure that the firing mechanism for stapling head assembly (300)completes a full actuation stroke in response to actuation of firingtrigger (150). In other words, it may be desirable to prevent subsequentmanipulation of firing trigger (150) from having any effect on thefiring mechanism completing the actuation stroke of stapling headassembly (300). In some instances, instrument (10) may incorporatemechanical features that ensure completion of a full actuation stroke ofstapling head assembly (300) in response to actuation of firing trigger(150), regardless of subsequent manipulation of firing trigger (150).Examples of such mechanical features are described in U.S. Pat. No.9,907,552, entitled “Control Features for Motorized Surgical StaplingInstrument,” issued Mar. 6, 2018, the disclosure of which isincorporated by reference herein. In addition to or as an alternative tousing such mechanical features, instrument (10) may include electroniccomponents that ensure completion of a full actuation stroke of staplinghead assembly (300) in response to actuation of firing trigger (150),regardless of subsequent manipulation of firing trigger (150). Severalexamples of such electrical features are described in greater detailbelow, while further examples will be apparent to those of ordinaryskill in the art in view of the teachings herein.

VII. Exemplary Battery Pack with Self-Draining Feature

FIGS. 41-57 depict instrument (10) including an exemplary battery pack(5600) that is configured to operate substantially similar to batterypack (120) discussed above except for any difference discussed below.For instance, battery pack (5600) is operable to provide electricalpower to a motor (161) in pistol grip (112) as discussed above withreference to battery pack (120). Battery pack (5600) is removable fromhandle assembly (100). In particular, as shown in FIGS. 41-42 and45A-45B, battery pack (5600) may be inserted into socket (116) definedby casing (110). Once battery pack (5600) is fully inserted in socket(116), latches (5602) of battery pack (5600) may resiliently engageinterior features of casing (110) to provide a snap fit. To removebattery pack (5600), the operator may press latches (5602) inwardly todisengage latches (5602) from the interior features of casing (110) thenpull battery pack (5600) proximally from socket (116). It should beunderstood that battery pack (5600) and handle assembly (100) may havecomplementary electrical contacts, pins and sockets, and/or otherfeatures that provide paths for electrical communication from batterypack (5600) to electrically powered components in handle assembly (100)when battery pack (5600) is inserted in socket (116).

As best seen in FIG. 43, battery pack (5600) includes an upper batteryhousing (5610) and a lower battery housing (5620). Upper battery housing(5610) and lower battery housing (5620) are configured to be secured toone another via ultrasonic welding (or using any other suitabletechnique) so as to provide a rigid casing that encloses a plurality ofbatteries (5630). Lower battery housing (5620) includes a positivebattery contact (5622) configured to connect with a positive terminal ofbatteries (5630) and a negative battery contact (5624) configured toconnect with a negative terminal of batteries (5630). Lower batteryhousing (5620) further includes a drain contact (5626). A proximal endof positive battery contact (5622) is biased toward drain contact(5626). As will be discussed in more detail below, contact betweenpositive battery contact (5622) and drain contact (5626) is configuredto drain batteries (5630) of power. It should be understood that casing(110) of instrument (10) and upper battery housing (5610) and batteries(5630) of battery pack (5600) have been omitted from FIGS. 46-57 toassist in understanding operation of battery pack (5600).

Lower battery housing (5620) includes a battery drain sled (5628) thatis slidably disposed within a channel (5621) formed within lower batteryhousing (5620) such that battery drain sled (5628) is configured totranslate longitudinally within channel (5621) relative to lower batteryhousing (5620). As shown in FIGS. 46-48, in an initial position, batterydrain sled (5628) positioned within channel (5621) between drain contact(5626) and the proximal end of positive battery contact (5622) so as toprevent contact between drain contact (5626) and positive batterycontact (5622).

As shown in FIGS. 49-50, as battery pack (5600) is inserted into socket(116) of casing (110), a flange (111) of right chassis portion (3693) ofchassis (3690) passes through an opening (5618) formed in a distal endof lower battery housing (5620) toward channel (5621) of lower batteryhousing (5620).

As shown in FIGS. 51-52, as battery pack (5600) is further inserted intosocket (116) of casing (110), flange (111) passes further throughopening (5618) and into channel (5621) such that a proximal end offlange (111) comes into contact with a distal end of battery drain sled(5628).

As shown in FIGS. 53-54, as battery pack (5600) is further inserted intosocket (116) of casing (110) to a point where battery pack (5600) isfully seated within socket (116), flange (111) passes further throughopening (5618) and into channel (5621) such that flange (111) drivesbattery drain sled (5628) proximally within channel (5621). In thisposition, battery drain sled (5628) is no longer between positivebattery contact (5622) and drain contact (5626). However, flange (111)is now positioned between positive battery contact (5622) and draincontact (5626). Thus, it should be understood that as battery pack(5600) is passed into socket (116), battery drain sled (5628) and flange(111) cooperate to prevent contact between positive battery contact(5622) and drain contact (5626).

As best seen in FIG. 54, as battery drain sled (5628) is drivenproximally, a detent (5629) of battery drain sled (5628) engages adetent (5619) formed in a sidewall of channel (5621) so as to “lock”battery drain sled (5628) in the proximal position. As shown in FIGS.55-57, as battery pack (5600) is removed, flange (111) is removed fromlower battery housing (5620) such that flange (111) is no longer betweenpositive battery contact (5622) and drain contact (5626). Thus, withbattery drain sled (5628) in the proximal position, the proximal end ofpositive battery contact (5622) contacts drain contact (5626) so as todrain batteries (5630) of power. Thus, it should be understood thatinsertion and removal of battery pack (5600) from casing (110) willultimately drain batteries (5630). In other words, battery pack (5600)will be drained of power after a single use. Such power drainage willfurther eliminate potential energy available from battery contacts(5622, 5624) so as to limit the chances of battery pack (5600) ignitingcombustible materials upon disposal.

FIG. 58 shows an exemplary battery drain circuit (5700) that may be usedto drain batteries (5630) as described above. As shown, circuit (5700)of this example includes a drain switch (5640) that is closed whenbattery pack (5600) is inserted into casing (110). In this example,drain switch (5640) remains open before battery pack (5600) is initiallyinserted into casing (110); and remains closed even after battery pack(5600) is removed from casing (110). When drain switch (5640) is closed,batteries (5630) are placed in communication with a pair of drainresistors (5642). Drain resistors (5642) are placed in series with eachother and in parallel with the remaining circuit (2700) of instrument(10). Drain resistors (5642) will continuously drain power frombatteries (5630) upon closure of drain switch (5640). In some othervariations, drain switch (5640) remains open until battery pack (5600)is removed from casing (110). In other words, battery drain circuit(5700) may be configured such that drain switch (5640) is only closedupon removal of battery pack (5600) from casing (110).

As also shown in FIG. 58, battery drain circuit (5700) of the presentexample also includes a fuse (5650). By way of example only, fuse (5650)may comprise a positive temperature coefficient (PTC) current limitingdevice. Fuse (5650) may thus control current during discharge ofbatteries (5630) so as to minimize any temperature rise in battery pack(5600) and/or its components. For instance, fuse (5650) may beconfigured to limit the temperature of battery pack (5600) and/or itscomponents to below a flash point of common materials encountered duringuse or upon disposal. Various suitable materials and configurations thatmay be used to form fuse (5650) will be apparent to those of ordinaryskill in the art in view of the teachings herein.

VIII. Exemplary Activation Circuit

Firing trigger (150) is operable to activate motor (161) to therebyactuate stapling head assembly (300). Safety trigger (140) is operableto selectively block actuation of firing trigger (150) based on thelongitudinal position of anvil (400) in relation to stapling headassembly (300). Firing trigger (150) may thus not be actuated untilafter safety trigger (140) has been actuated. Handle assembly (100) alsoincludes components that are operable to selectively lock out bothtriggers (140, 150) based on the position of anvil (400) relative tostapling head assembly (300). When triggers (140, 150) are locked out,safety trigger (140) is prevented from moving to permit actuation offiring trigger (150), and firing trigger (150) is prevented frominitiating actuation of stapling head assembly (300). Thus, firingtrigger (150) is only operable to initiate actuation of stapling headassembly (300) when the position of anvil (400) relative to staplinghead assembly (300) is within a predefined range. By way of exampleonly, such lockout features may be constructed and operable inaccordance with at least some of the teachings of U.S. Pat. No.10,307,157, entitled “Surgical Stapler with Anvil Seating Detection,”issued Jun. 4, 2019, the disclosure of which is incorporated byreference herein.

As best seen in FIGS. 59A-59B, firing trigger (150) of the presentexample includes an integral actuation paddle (158). In scenarios whensafety trigger (140) has been actuated to permit actuation of firingtrigger (150), paddle (158) pivots forwardly as firing trigger (150)pivots from the position shown in FIG. 59A to the position shown in FIG.59B. Paddle (158) is configured to actuate a switch (182) (see FIG. 60)of a motor activation module (180) when firing trigger (150) pivots fromthe position shown in FIG. 59A to the position shown in FIG. 59B. Switch(182) of motor activation module (180) is in communication with batterypack (120) and motor (161), such that motor activation module (180) isconfigured to provide activation of motor (161) with electrical powerfrom battery pack (120) in response to paddle (158) actuating switch(182) of motor activation module (180). Thus, motor (161) will beactivated when firing trigger (150) is pivoted from the position shownin FIG. 59A to the position shown in FIG. 59B. This activation of motor(161) will actuate stapling head assembly (300) as described herein. Byway of example only, this actuation may be carried out in accordancewith at least some of the teachings of U.S. Pub. No. 2016/0374666,entitled “Surgical Stapler with Reversible Motor,” published Dec. 29,2016, issued as U.S. Pat. No. 10,456,134 on Oct. 29, 2019, thedisclosure of which is incorporated by reference herein. An exemplaryway in which motor activation module (180) may be integrated into acontrol circuit (2700) will be described in greater detail below withreference to FIG. 60. Other examples will be apparent to those ofordinary skill in the art in view of the teachings herein.

As noted above, paddle (806) is configured to actuate switch buttons(192) of motor stop module (190) at the end of an actuation stroke ofstapling head assembly (300). In the present example, motor stop module(190) reverses the polarity of electrical power provided to motor (161)when switch buttons (192) are actuated. This results in dynamic brakingof motor (161) once an actuation stroke of stapling head assembly (300)has been completed. By way of example only, motor stop module (190) maybe configured and operable in accordance with at least some of theteachings of U.S. Pat. No. 9,907,552, issued Mar. 6, 2018, thedisclosure of which is incorporated by reference herein. Other suitableconfigurations will be apparent to those of ordinary skill in the art inview of the teachings herein.

Those of ordinary skill in the art will recognize that, during normaluse of instrument (10), at least certain portions of instrument (10) maybe exposed to various fluids, including but not limited to patientbodily fluids, saline, etc. By way of example only, the regions ofinstrument (10) that may be most susceptible to liquid ingress mayinclude stapling head assembly (300) and features at or near theunderside of handle assembly (100), where liquid may tend to gatherafter running down shaft assembly (200). Those of ordinary skill in theart will also recognize that some electrical circuit components mayexperience compromised performance when such electrical circuitcomponents are exposed to liquids. For instance, liquids may compromisethe functioning of some electrical circuits and circuit components. Inthe context of a surgical instrument like instrument (10), a compromisedcircuit may cause a feature (e.g., motor (161) and thus stapling headassembly (300)) to activate prematurely, which may provide anundesirable outcome. It may therefore be desirable to provide a versionof instrument (10) where ingress of liquid onto certain electricalcircuit components will not compromise the performance of suchelectrical circuits and circuit components by causing prematureactivation or other undesirable effects.

While the following examples are provided in the context of a variationof instrument (10), the same teachings may be readily incorporated intovarious other kinds of surgical instruments. Other kinds of instrumentsto which the below teachings may be applied will be apparent to those ofordinary skill in the art.

FIG. 60 shows an exemplary control circuit (2700) that may beincorporated into instrument (10). Circuit (2700) is configured suchthat ingress of liquid onto dome switch (2610) and motor activationmodule (180) will not compromise the performance of dome switch (2610),motor activation module (180), or motor stop module (190). Dome switch(2610) and motor activation module (180) are thus within a liquid-immuneregion (750) of circuit (2700). As shown, circuit (2700) of this exampleincludes several transistors (2710, 2712, 2714, 2716, 2718), severalresistors (2720, 2722, 2724, 2726, 2728, 2730, 2732, 2734, 2736),several schottky diodes (2740, 2742, 2744, 2746), a zener diode (2748),and a capacitor (2749). As also shown, battery pack (120), motor (161),motor activation module (180), switch buttons (192), dome switch (2610),and LEDs (2702, 2704) are also incorporated into circuit (2700). In thepresent example, control circuit (2700) is configured such that theelectrical current flow to dome switch (2610) is less than the currentflow to motor (161).

In the present example, transistor (2710), motor activation module(180), and resistors (2720, 2722) are all located within liquid-immuneregion (2750) of circuit (2700). Transistor (2710) of the presentexample has a relatively low voltage threshold and is in communicationwith dome switch (2610), motor activation module (180), and othercomponents that are ultimately coupled with motor (161). In the presentexample, switch (182) of motor activation module (180) is configuredsuch that switch (182) is held in a closed state by default. Thus, whenpaddle (158) engages motor activation module (180) in response to theoperator pivoting firing trigger (150), paddle (158) transitions switch(182) of motor activation module (180) from a closed state to an openstate.

Transistor (2710) and the associated components of circuit (2700) areconfigured to provide activation of motor (161) only when the switch ofmotor activation module (180) is in the open state (which would indicatethat firing trigger (150) has been fully actuated) and when dome switch(2610) is in the closed state (which would indicate that anvil (400) isproperly coupled with trocar (330)). Thus, motor (161) will not beactivated when the switch of motor activation module (180) is in theclosed state (which would indicate that firing trigger (150) has notbeen fully actuated), even if dome switch (2610) is in a closed state.Similarly, motor (161) will not be activated when dome switch (2610) isin an open state (which would indicate that anvil (400) is not properlycoupled with trocar (330)), even if the switch of motor activationmodule (180) is in the open state.

Those of ordinary skill in the art will recognize that a switch that isflooded with liquid may tend to be compromised, which may prematurelyproduce the effect of a closed switch. Thus, in alternative versions ofcircuit (2700) where motor (161) is activated upon the transition of theswitch of motor activation module (180) from an open state to a closedstate, liquid ingress may compromise the switch to thereby effectivelyprovide a closed state before firing trigger (150) is actuated. In otherwords, in alternative versions of circuit (2700) where motor (161) isactivated upon the transition of the switch of motor activation module(180) from an open state to a closed state, liquid ingress may result inpremature activation of motor (161) and thus stapling head assembly(300). However, by requiring the switch of motor activation module (180)to be in an open state to provide activation of motor (161), circuit(2700) of the present example prevents motor (161) and thus staplinghead assembly (300) from being activated prematurely by liquid ingress.

When dome switch (2610) is in an open state (i.e., when anvil (400) hasnot actuated dome switch (2610) as described above), transistor (2710)acts as a closed switch (“on”). When dome switch (2610) is in a closedstate (i.e., when anvil (400) has actuated dome switch (2610) asdescribed above), transistor (2710) will behave as an open switch(“off”). Those of ordinary skill in the art will recognize that thevoltage threshold of transistor (2714) is equal to or greater than 0.7Vbecause the emitter (the point at which transistors (2714, 2716) areconnected) is connected to 0V of the battery. When the point at whichcapacitor (2749), resistors (2728, 726), and transistor (2714) connectexceeds this threshold, transistor (2714) will act a closed switch(“on”), thereby allowing motor (161) to activate.

Transistor (2714) has a relatively low voltage threshold in the presentexample. Transistor (2714) is thus capable of recognizing an open stateof switch (182) of motor activation module (180), even if motoractivation module (180) is flooded with electrically conductive liquid,due to the fact that the liquid provides enough resistivity that it doesnot create an equivalency to a closed switch. The liquid's resistivitywill lower the voltage but not to a level below the low voltagethreshold of transistor (2710), thus allowing the transistor (2710) torecognize that switch (182) has been opened.

In addition to, or as an alternative to, providing the configuration ofcircuit (2700) described above, various electrical components may becoated with a liquid-impermeable coating to provide at least some degreeof immunity to liquid ingress. For instance, in some versions, one ormore printed circuit boards of circuit (2700) (e.g., a circuit board towhich LEDs (2702, 2704) are mounted) may be coated with aliquid-impermeable coating. In addition, or in the alternative, eitheror both of LEDs (2702, 2704) may be coated with a liquid-impermeablecoating. Other features of circuit (2700) that may be coated with aliquid-impermeable coating will be apparent to those of ordinary skillin the art in view of the teachings herein.

In some versions where a liquid-impermeable coating is used on one ormore components of circuit (2700), the liquid-impermeable coating maycomprise an ultraviolet-cured urethane coating. In some versions, theliquid-impermeable coating is transparent. By making the coatingtransparent, this may preserve legibility of coated features that areintended to be viewed (e.g., either or both of LEDs (2702, 2704)).Moreover, in versions where one or both of LEDs (2702, 2704) is/arecoated, use of a transparent coating may prevent the light emitted fromthe coated LED (2702, 2704) from being transmitted along the coating(i.e., “bleeding”). Other various suitable materials that may be used toprovide such coatings, and various methods that may be used to applysuch coatings, will be apparent to those of ordinary skill in the art inview of the teachings herein.

IX. Exemplary Conical Coil Springs

As described above, instrument (10) may include a body (e.g. handleassembly (100)), a shaft (e.g. shaft assembly (200)), a stapling headassembly (e.g. stapling head assembly (300)), and an anvil (e.g. anvil(400)). Shaft assembly (200) extends distally from handle assembly(100), and stapling head assembly (300) is positioned at distal end ofshaft assembly (200). Handle assembly (100) includes a chassis (e.g.chassis (3690) that may include left and right chassis portions (3691,3693)), bracket (3650), and a coupling (e.g. nut (160)).

FIG. 61 shows a detailed view of coil spring (170) of FIG. 18. As shown,coil spring (170) includes a proximal end (6012), a distal end (6014),and helical coils (6016) disposed between proximal and distal ends(6012, 6014). Proximal and distal ends (6012, 6014) may be ground tohave flat ends.

It would be desirable to prevent distal end (6014) of coil spring (170)from potentially being inadvertently caught (e.g. pinched) betweenbracket (3650) and chassis (3690), as coil spring (170) moves betweenfirst and second positions as safety trigger (140) is actuated.Additionally, it would be beneficial to ensure that coil spring (170) iscorrectly installed within the instrument (e.g. instrument (10)). Assuch, coil spring (170) of FIG. 61 may be interchanged with first,second, and third exemplary conical coil springs (6110, 6210, 6310) asshown and described below with reference to FIGS. 62-65. In other words,conical coil spring (6110, 6210, 6310) may be used in place of coilspring (170) and be suitably incorporated into instrument (10) withoutadditional modifications.

A. First Exemplary Conical Coil Spring

FIGS. 62-63 show a first exemplary conical coil spring (6110). FIG. 62shows a bottom view of trocar actuation rod (220) of FIG. 17, rightchassis portion (3693) of chassis (3690) and nut (160) of FIG. 18,bracket (3650) of FIG. 35, left chassis portion (3691) of FIG. 37, andconical coil spring (6110). As previously described, bracket (3650),also referred to a safety release plate, is configured to move relativeto left and right chassis portions (3691, 3693) of chassis (3690)between first and second positions when selectively activated by a user.As described above, it is also envisioned at bracket (1500) may be usedin place of bracket (3650). As shown, conical coil spring (6110) isdisposed between bracket (3650) and nut (160).

As shown in FIGS. 62-63, conical coil spring (6110) includes a proximalend (6112), a distal end (6114), and a conical helical body (6115)disposed between proximal and distal ends (6112, 6114). Conical helicalbody (6115) includes a plurality of conical helical coils (6116).Conical coil spring (6110) includes at least one dead coil (6118)disposed at distal end (6114) of conical coil spring (6110). An activecoil is a coil that stores and releases energy (e.g. conical helicalcoils (6116)). Conversely, a dead coil (i.e. an inactive coil) is a coilthat does not store and release energy, such that the dead coil does notcontribute to the motive force of the coil spring. FIG. 63 shows threedead coils (6118), however, more or fewer dead coils (6118) areenvisioned. Dead coils (6118) may prevent distal end (6114) of conicalcoil spring (6110) from being inadvertently caught (e.g. pinched)between bracket (3650) and chassis (3690). Dead coils (6118) are alsoconfigured to prevent conical coil spring (6110) from catching on finehelical threading (226) of trocar actuation rod (220). Dead coils (6118)may also assist in identifying the orientation of conical coil spring(6110) to ensure correct installation of conical coil spring (6110)within an instrument (e.g. instrument (10)).

As shown in FIGS. 62-63, a bent-back portion (6120) generally disposedat distal end (6114) is bent back a distance (dl) toward proximal end(6112). Bent-back portion (6120) also ensures that conical coil spring(6110) is correctly installed within the instrument (e.g. instrument(10)), and that the instrument cannot be assembled incorrectly (whileproximal end (6112) or distal end (6114) are disposed between bracket(3650) and left chassis portion (3691) of chassis (3690)). FIG. 63 showsa detailed view of conical coil spring (6110) of FIG. 62. Proximal end(6112) of conical coil spring (6110) has a first circumference (C1 a).Likewise, distal end (6114) of conical coil spring (6110) has a secondcircumference (C2 a) that is smaller than first circumference (C1 a).Second circumference (C2 a) being is smaller than first circumference(C1 a) enables distal end (6114) of conical coil spring (6110), having adiameter (D), to include bent-back portion (6120) that is bent adjacentan outside (6122) of conical helical body (6115) without protruding pastfirst circumference (C1 a) of proximal end (6112) of conical coil spring(6110). As a result of the conical shape, conical coil spring (6110) mayfit in the same space as coil spring (170), even with conical coilspring (6110) including bent-back portion (6120).

As shown in FIG. 62, nut (160) includes a proximal flange (6020) that issmaller than the first circumference (C1 a) of conical coil spring(6110). Additionally, as shown in FIG. 62, nut (160) includes a bodyportion (6022) that is larger than first circumference (C1 a) of conicalcoil spring (6110). Body portion (6022) includes an opening (shown inFIG. 18) that extends through proximal flange (6020) of nut (160) andbody portion (6022) of nut (160), such that the opening is configured toreceive trocar actuation rod (220) therethrough. Proximal end of trocaractuation rod (220) extends through opening (7204) in upright member(3652) of bracket (3650) and through conical coil spring (6110).

Instead of or in addition to incorporating conical coil springs (6110,6210, 6310) in place of coil spring (170), a weld (not shown) mayfixably couple distal end (6014) of coil spring (170) or distal end(6114, 6214, 6314) of conical coil spring (6110, 6210, 6310) to bracket(3650). Similarly, while not shown, adjacent coils of proximal end(6012) of coil spring (170) or proximal end (6112, 6212, 6312) ofconical coil spring (6110, 6210, 6310) and/or adjacent coils of distalend (6014) of coil spring (170) or distal end (6114, 6214, 6314) ofconical coil spring (6110, 6210, 6310) may be welded together. Insteadof or in addition to incorporating conical coil springs (6110, 6210,6310) in place of coil spring (170), alternative spring terminal endsmay also be incorporated.

B. Second Exemplary Conical Coil Spring

FIG. 64 shows a detailed view of a second exemplary conical coil spring(6210). As described above, conical coil spring (6210) may be used inplace of coil spring (170) or conical coil spring (6110). As shown,conical coil spring (6210) includes a proximal end (6212), a distal end(6214), and a conical helical body (6215) disposed between proximal anddistal ends (6212, 6214). Conical helical body (6215) includes conicalhelical coils (6216). Conical coil spring (6210) includes at least onedead coil (6218) disposed at distal end (6214) of conical coil spring(6210). FIG. 64 shows two dead coils (6218), however, more or fewer deadcoils (6218) are envisioned. Dead coils (6218) may prevent distal end(6214) of conical coil spring (6210) from being inadvertently pinchedbetween bracket (3650) and chassis (3690). Dead coils (6218) are alsoconfigured to prevent conical coil spring (6210) from catching on finehelical threading (226) of trocar actuation rod (220). Dead coils (6218)may assist in identifying the orientation of conical coil spring (6210)to ensure correct installation of conical coil spring (6210). Proximalend (6212) of conical coil spring (6210) has a first circumference (C1b). Likewise, distal end (6214) of conical coil spring (6210) has asecond circumference (C2 b) that is smaller than first circumference (C1b). Second circumference (C2 b) being is smaller than firstcircumference (C1 b) ensures correct installation of conical coil spring(6210).

C. Third Exemplary Conical Coil Spring

FIG. 65 shows a detailed view of a third exemplary conical coil spring(6310). As described above, conical coil spring (6310) may be used inplace of coil spring (170) or conical coil springs (6110, 6210). Asshown, conical coil spring (6310) includes a proximal end (6312), adistal end (6314), and a conical helical body (6315) disposed betweenproximal and distal ends (6312, 6214). Conical helical body (6315)includes conical helical coils (6316). Conical coil spring (6310)includes at least one dead coil (6318) disposed at distal end (6314) ofconical coil spring (6310). FIG. 65 shows three dead coils (6318),however, more or fewer dead coils (6318) are envisioned. Dead coils(6318) may prevent distal end (6314) of conical coil spring (6310) frombeing inadvertently pinched between bracket (3650) and chassis (3690).Dead coils (6318) are also configured to prevent conical coil spring(6310) from catching on fine helical threading (226) of trocar actuationrod (220). Dead coils (6318) may assist in identifying the orientationof conical coil spring (6310) to ensure correct installation of conicalcoil spring (6310). Proximal end (6312) of conical coil spring (6310)has a first circumference (C1 c). Likewise, distal end (6314) of conicalcoil spring (6310) has a second circumference (C2 c) that is smallerthan first circumference (C1 c). Second circumference (C2 c) being issmaller than first circumference (C1 c) ensures correct installation ofconical coil spring (6310).

X. Additional Modifications

Alternatively, or in addition to incorporating conical coil spring(6110, 6210, 6310) in place of coil spring (170), additionalmodifications may be incorporated into instrument (10). As will bedescribed below with reference to FIGS. 66-74, these additionalmodifications may include an exemplary slidable coupling (6410), anexemplary guide bushing (6510), an exemplary centering feature (6612) onan exemplary bracket (6610), and/or an exemplary sleeve (6710). Othermodifications are also envisioned. For example, while not shown, leftchassis portion (3691) may also include a cutout configured to preventdistal end (6014) of coil spring (170) or distal end (6114, 6214, 6314)of conical coil spring (6110, 6210, 6310) from being pinched.

As shown in FIG. 35 and below in FIG. 66, bracket (3650) is configuredto move along a longitudinal axis between first and second positionswhen selectively activated by a user. Bracket (3650) includes proximaland distal portions (3678, 3680). Proximal portion (3678) includesflared-out portions (3682) disposed along the longitudinal axis.Proximal portion (3678) also includes upright member (3652) disposedperpendicular to flared-out portions (3682). Upright member (3652) ofbracket (3650) includes inner and outer surfaces (3686, 3688) (see FIG.68).

A. Exemplary Slidable Coupling

FIG. 66-69 show various perspective views of slidable coupling (6410).Particularly, FIG. 66 shows a perspective view of bracket (3650) of FIG.35 coupled with coil spring (170) of FIG. 61 using slidable coupling(6410). FIG. 67 shows a detailed perspective portion of FIG. 66, andFIG. 68 shows an exploded perspective view of FIG. 66. Slidable coupling(6410) is configured to retain distal end (6114) of coil spring (170)and upright member (3652). As shown in FIGS. 68-69, slidable coupling(6410) includes a body portion (6412) that may be shaped to generallycorrespond to the profile of upright member (3652). Slidable coupling(6410) includes first and second arms (6414, 6416) spaced longitudinallyfrom body portion (6412). As shown, slidable coupling (6410) isintegrally formed together as a unitary piece. For example, slidablecoupling (6410) may be formed from one or more stamping operations (e.g.from a thin plate of metal).

As shown in FIG. 69, first arm (6414) is connected with body portion(6412) by a first lateral portion (6418), and second arm (6416) isconnected with body portion (6412) by a second lateral portion (6420).Body portion (6412) includes an arcuate upper portion (6422) thatincludes an arcuate opening (6424) configured to receive a proximal endof trocar actuation rod (220). As previously described, arcuate upperportion (6422) may be shaped to generally correspond to the profile ofupright member (3652). First and second arms (6414, 6416) respectivelyinclude first and second upwardly extending portions (6426, 6428) andfirst and second inner surfaces (6430, 6432). As shown, first and secondinner surfaces (6430, 6432) of first and second arms (6414, 6416) alongwith an inner surface (6434) of body portion (6412) are configured tolongitudinally retain distal end (6014) of coil spring (170) and uprightmember (3652) of bracket (3650). Particularly, inner surface (6434) ofbody portion (6412) is disposed against inner surface (3686) of uprightmember (3652). Additionally, outer surface (3688) of upright member(3652) is disposed against distal end (6014) of coil spring (170), anddistal end (6014) of coil spring (170) is also disposed against firstand second inner surfaces (6430, 6432) of first and second arms (6414,6416). Additionally, first and second lateral portions (6418, 6420)center coil spring (170) by bounding coil spring (170) in the directionperpendicular to the longitudinal direction.

First lateral portion (6418) is partially obstructed from view in FIG.69 but is a mirror image of second lateral portion (6420). This mayprevent lateral movement of coil spring (170). As such, slidablecoupling (6410) may prevent distal end (6014) of coil spring (170) ordistal end (6114, 6214, 6314) of conical coil spring (6110, 6210, 6310)from being pinched. Slidable coupling (6410) may be incorporated intoinstrument (10) alternatively, or in addition to, incorporating conicalcoil spring (6110, 6210, 6310) in place of coil spring (170).

B. Exemplary Guide Bushing

FIGS. 70-71 show an exemplary guide bushing (6510). FIG. 70 shows anexploded perspective view of trocar actuation rod (220) of FIG. 17, nut(160) and coil spring (170) of FIG. 18, as well as bracket (3650) ofFIG. 35, and guide bushing (6510). FIG. 71 shows a detailed perspectiveview of guide bushing (6510) of FIG. 70. As shown in FIG. 70, guidebushing (6510) is configured to be coupled between upright member (3652)and coil spring (170). Guide bushing (6510) includes a generally annularbody (6512). If desired, guide bushing (6510) may be fixably coupledwith upright member (3652) using a variety of methods (e.g. adhesive orwelding). Body (6512) includes a first portion (6514) having a firstouter diameter (OD1) and a second portion (6516) (e.g. a receivingportion) having a second outer diameter (OD2). First outer circumference(OD1) is greater than the circumference (C) of distal end (6014) of coilspring (170), while second outer circumference (OD2) is less than thecircumference (C) of distal end (6014) of coil spring (170). Trocaractuation rod (220) is configured to pass through an opening (6518) ofguide bushing (6510). As shown, second portion (6516) includesprojections (6018) that are configured to retain distal end (6014) ofcoil spring (170). As shown, projections 6018) include an arcuatesurface (6522) that increases outer diameter of second portion (5614)moving toward first portion (6514). As such, guide bushing (6510) mayprevent distal end (6014) of coil spring (170) or distal end (6114,6214, 6314) of conical coil spring (6110, 6210, 6310) from beingpinched. Guide bushing (6510) may be incorporated into instrument (10)alternatively, or in addition to, incorporating conical coil spring(6110, 6210, 6310) in place of coil spring (170).

C. Exemplary Centering Feature

FIG. 72 shows a perspective view of conical coil spring (6110) of FIG.62 and an exemplary alternative bracket (6610) that includes anexemplary centering feature (6612). Bracket (6610) is similar to bracket(3650), but with bracket (6610) additionally including centering feature(6612). Similar to bracket (3650), bracket (6610) is shown as includingupright member (6652) similar to upright member (3652), opening (6654)similar to opening (7204), flared out portions (6682), similar toflared-out portions (3682), and outer surface (6688) similar to outersurface (3688). Other features of bracket (6610) are not shown, whichmay be the similar or the same as bracket (3650).

As shown, centering feature (6612) is disposed on outer surface (6688)of bracket (6610). Centering feature (6612) is configured to retaindistal end (6114) of conical coil spring (6110). Centering featureincludes first and second projections (6614, 6616). As shown, first andsecond projections (6614, 6616) are separated by opening (6654). Firstprojection (6614) includes a first inner surface (6618) and secondprojection (6616) includes a second inner surface (6620). First andsecond inner surfaces (6618, 6620) allow trocar actuation rod (220) topass through unimpeded. While centering feature (6612) is shaped as acuboid, it is envisioned that centering feature (6612) may have avariety of shapes and sizes. First and second projections (6614, 6616)may be integrally formed as a unitary piece with bracket (6610), oralternatively, first and second projections (6614, 6616) may besubsequently fixably coupled with bracket (6610) using a variety ofmethods (e.g. adhesive or welding). Centering feature (6612) may preventdistal end (6114) of conical coil spring (6110) from moving laterally(i.e. in a direction perpendicular to the longitudinal axis). As such,centering feature (6612) may prevent distal end (6014) of coil spring(170) or distal end (6114, 6214, 6314) of conical coil spring (6110,6210, 6310) from being pinched. Centering feature (6612) may beincorporated into instrument (10) alternatively, or in addition to,incorporating conical coil spring (6110, 6210, 6310) in place of coilspring (170).

D. Exemplary Sleeve

FIGS. 73-74 show an exemplary sleeve (6710). FIG. 73 shows a perspectiveview of bracket (3650) and conical coil spring (6110) of FIG. 62, butwith conical coil spring (6110) partially disposed within sleeve (6710).FIG. 74 shows a detailed perspective view of conical coil spring (6110)and sleeve (6710) of FIG. 73. Sleeve (6710) includes a body (6712)having proximal and distal ends (6714, 6716). Body (6712) includes innerand outer surfaces (6718, 6720). Sleeve (6710) includes a proximal wall(6722) and an inner opening (6724) configured to allow trocar actuationrod (220) to extend therethrough. Sleeve (6710) circumferentiallysurrounds proximal end (6112) of conical coil spring (6110) and isconfigured to prevent proximal end (6112), i.e. the tail, from beinginadvertently pinched. Sleeve (6710) may be incorporated into instrument(10) alternatively, or in addition to, incorporating conical coil spring(6110, 6210, 6310) in place of coil spring (170).

XI. Exemplary Chassis

A. Left Chassis Portion without Longitudinal Rib

FIGS. 75-77 show various views of bracket (3650) of FIG. 35 disposedwithin left chassis portion (3691). FIG. 76 shows a detailed perspectiveview of bracket (3650) and left chassis portion (3691) of FIG. 75. FIG.77 shows a perspective view of bracket (3650) and left chassis portion(3691) of FIG. 76 from another angle. As shown, left chassis portion(3691) includes first and second vertically extending ribs (3696, 3698)that extend generally perpendicular to longitudinal axis (LA).

B. Exemplary Left Chassis Portion with Longitudinal Rib

FIGS. 78-79 depict an exemplary alternative left chassis portion (6750)that is similar to left chassis portion (3691), but with left chassisportion (6750) including a longitudinal rib (6756). FIG. 78 shows a rearelevational view of bracket (3650) of FIG. 35 disposed within leftchassis portion (6750) of longitudinal rib (6756). FIG. 79 shows a rightperspective view of bracket (3650) and left chassis portion (6750) ofFIG. 78.

Proximal portion (3678) of bracket (3650) includes flared-out portions(3682) disposed along longitudinal axis (LA). Proximal portion (3678)also includes upright member (3652) disposed perpendicular to flared-outportion (3682). Flared-out portions (3682) include a flared-out distalsurface (3684). Upright member (3652) of bracket (3650) includes innerand outer surfaces (3686, 3688). Left chassis portion (6750) includesfirst and second vertically extending ribs (6752, 6754) that extendgenerally perpendicular to longitudinal axis (LA). Longitudinallyextending rib (6756) extends generally parallel to longitudinal axis(LA) and abuts first vertically extending rib (6752). Longitudinallyextending rib (6756) is configured to prevent bracket (3650) fromcontacting first vertically extending rib (6752). As a result,longitudinal rib (6756) may prevent bracket (3650) from become fixed(e.g. stuck). Second vertically extending rib (6754) abutslongitudinally extending rib (6756). Coil spring (170) or conical coilspring (6110, 6210, 6310) is configured to be disposed between uprightmember (3652) of bracket (3650) and nut (160).

XII. Exemplary Guidance Track

A. Guidance Track without Raised Portion

FIG. 80 shows a perspective view of protrusion (141) of safety trigger(140) of FIG. 31 interacting with right chassis portion (3693) of FIG.18 taken from another angle. As shown, right chassis portion (3693)includes a projecting portion (6812). Projecting portion (6812) includesa guidance track (6814). Guidance track (6814) includes first and seconddetents (6816, 6818) separated by a channel (6820). First detent (6816)is configured to receive protrusion (141) of safety trigger (140) in thesafety engaged position (i.e. locked out position). Second detent (6818)is configured to receive protrusion (141) of safety trigger (140) in thesafety disengaged position (i.e. ready to be fired position). Channel(6820) is configured to receive protrusion (141) of safety trigger (140)when safety trigger (140) is moved between the safety engaged and thesafety disengaged positions. Safety trigger (140) is configured totransition when selectively activated by the user from the engagedposition that prevents actuation of instrument (10) to the disengagedposition that enables actuation of instrument (10).

In other words, protrusion (141) is configured to cooperate with firstdetent (6816) of right chassis portion (3693), to selectively retainsafety trigger (140) in the flipped-up position shown in FIGS. 30D-30E.Protrusion (141) is configured to prevent inadvertent movement of safetytrigger (140) from the flipped-up position (FIGS. 30D-30E) to theflipped-down position (FIGS. 30A-30C).

B. Exemplary Guidance Track with Raised Portion

As previously described with reference to FIG. 80, safety trigger (140)is configured to transition when selectively activated by the user fromthe engaged position that prevents actuation of the instrument (e.g.instrument (10)) to the disengaged position that enables actuation ofthe instrument. It is desirable to allow safety trigger (140) to only beactuated within the desired tissue gap range. When safety trigger (140)is left in an intermediate position (not within first and second detents(6816, 6818) of guidance track (6814)), it may be possible to fireinstrument (10). As such, it would desirable to prevent safety trigger(140) from being able to rest in the intermediate position, which may beoutside of the indicated desired tissue gap range. Preventing safetytrigger (140) from remaining in the intermediate position may beobtained by forcing safety trigger (140) to one of only the twofollowing acceptable positions: (1) the safety engaged position (i.e.locked out), or (2) the safety disengaged position (i.e. ready to befired).

FIG. 81 shows a perspective view of protrusion (141) of safety trigger(140) interacting with an exemplary alternative right chassis portion(6910). Right chassis portion (6910) includes a projecting portion(6912). Projecting portion (6912) includes a guidance track (6914).Guidance track (6914) includes a first detent (6916), a second detent(6918), a channel (6920), and a raised portion (6922). Unlike FIG. 80that does not include raised portion (6922), guidance track (6914) ofFIG. 81 includes raised portion (6922) that protrudes outwardly (e.g.upwardly) from channel (6920). Raised portion (6922) is configured toforce safety trigger (140) to either the engaged position or thedisengaged position, and not allow safety trigger (140) in remain in anintermediate position. In other words, raised portion (6922) of guidancetrack (6914) forces one of two discrete positions that force binaryon/off of safety trigger (140) that may prevent firing outside thedesired tissue gap range.

As shown in FIG. 81, raised portion (6922) includes a peak (6924) thatdefines a furthermost point that raised portion (6922) is disposed awayfrom the surface of channel (6920). As shown, peak (6924) is disposedcentrally (i.e. in the middle between) between first and second detents(6916, 6918). Raised portion (6922) includes a first downwardly slopingsurface (6926) that slopes downwardly from peak (6924) to first detent(6916). Similarly, raised portion (6922) includes a second downwardlysloping surface (6928) that slopes downwardly from peak (6924) to seconddetent (6918). As shown, first downwardly sloping surface (6926) slopesdownwardly the entire distance between peak (6924) and first detent(6916), and second downwardly sloping surface (6928) slopes downwardlythe entire distance between peak (6924) and second detent (6918). Firstand second downwardly sloping surfaces (6926, 6928) maintain the safetytrigger (140) in either the safety engaged position or the safetydisengaged position. As such, raised portion (6922) forces safetytrigger (140) into one of only two acceptable positions—either (1) thesafety engaged position (i.e. locked out), or (2) the safety disengagedposition (i.e. ready to be fired). This may reduce the possibility thatsafety trigger (140) may be left in the intermediate position betweenengaged and disengaged positions, which would be undesirable.

First detent (6916) is configured to receive protrusion (141) of safetytrigger (140) in the safety engaged position (i.e. locked out position).Second detent (6918) is configured to receive protrusion (141) of safetytrigger (140) in the safety disengaged position (i.e. ready to be firedposition). Raised portion (6922) is configured to receive protrusion(141) of safety trigger (140) when safety trigger (140) is moved betweenthe engaged and disengaged positions. As shown, guidance track (6914) isintegrally formed together as a unitary piece together with rightchassis portion (6910).

XIII. Illumination of User Feedback Feature by Main Circuit BoardAssembly

A. Overview of User Feedback Feature and Main Circuit Board Assembly

FIGS. 82 and 83 show additional details of user feedback feature (114)of handle assembly (100) and a main circuit board assembly (2760) ofcontrol circuit (2700) over which user feedback feature (114) ispositioned. As described above in connection with FIG. 32, user feedbackfeature (114) includes several feedback elements configured to enable auser to monitor certain conditions of instrument (10). One suchcondition is a closure position of anvil (400) relative to deck member(320) of stapling head assembly (300), and a resulting height of staplesto be formed in the tissue, indicated via a longitudinal position ofindicator needle (1526) within window (3570) of lens member (3550).Another such condition is whether the actuation stroke (or “firingstroke”) of stapling head assembly (300) has been completed, indicatedvia illumination of checkmark feature (3564) of lens member (3550). Asalso described above, window (3570) is illuminated by a first LED (2702)and checkmark feature (3564) is illuminated by a second LED (2704), bothLEDs (2702, 2704) being components of main circuit board assembly(2760). In the present version, window (3570) and first LED (2702) arearranged distally, and checkmark feature (3564) and second LED (2704)are arranged proximally.

As shown in FIGS. 82 and 83, a cover plate (3590) of user feedbackfeature (114) is positioned over lens member (3550), which in turn ispositioned over main circuit board assembly (2760). Cover plate (3590)includes a central opening (3592) configured to receive a primary bodyportion (3580) of lens member (3550). Proximally of central opening(3592), cover plate (3590) further includes a checkmark-shaped opening(3594) configured to receive a secondary body portion (3582) of lensmember (3550) that defines checkmark feature (3564). Distally of centralopening (3592), cover plate (3590) of further includes indicia field(3566), which indicates a size of stapling head assembly (300) in thepresent version. As shown best in FIG. 82, lens member (3550) of thepresent example is formed as a unitary structure having primary bodyportion (3580) and secondary body portion (3582) extending proximallyfrom primary body portion (3580). Primary body portion (3580) defineswindow (3570) and includes fixed linear indicia (3552, 3554, 3556) andstaple graphics (3560, 3562). Secondary body portion (3582) includes acap feature (3584) having a closed upper end that defines checkmarkfeature (3564).

As shown best in FIG. 83, main circuit board assembly (2760) of controlcircuit (2700) is supported by handle assembly chassis (3690) at alocation beneath user feedback feature (114). Main circuit boardassembly (2760) of the present version includes a circuit board (2762)that is electrically coupled with motor activation module (180) andmotor stop module (190) via a first plurality of wires (2764) on a firstlateral side of circuit board (2762); and is electrically coupled withmotor (161) via a second plurality of wires (2766) on a second lateralside of circuit board (2762). In the present example, circuit board(2762) is electrically coupled with anvil dome switch (2610) via motoractivation module (180).

B. Exemplary Alternative Main Circuit Board Assembly Having LightDirecting Features

In some instances, it may be desirable to configure main circuit boardassembly (2760) with features that control the illumination effects ofeach LED (2702, 2704). For instance, it may be desirable to providefeatures that inhibit window backlighting LED (2702) from illuminatingcheckmark feature (3564), thereby preventing false indications of firingstroke completion to the user. Such features may thus enable a user toensure that the distal end of surgical instrument (10) remainsstabilized within the patient during a surgical procedure until thefiring stroke is indeed complete. Such features may thus enhance userconfidence in safe and precise operation of instrument (10) during asurgical procedure.

FIGS. 84 and 85 show another exemplary main circuit board assembly(2770) configured for use with control circuit (2700) of surgicalinstrument (10), and which is similar to main circuit board assembly(2760) described above except as otherwise described below. Like maincircuit board assembly (2760), main circuit board assembly (2770) isconfigured to be supported by handle assembly chassis (3690) at alocation beneath user feedback feature (114). Main circuit boardassembly (2770) includes a circuit board (2772) that is electricallycoupled with motor activation module (180), motor stop module (190), andmotor (161) via wires (2774). A first LED (2776) is arranged at a distalend of an upper side of circuit board (2772), and a second LED (2778) isarranged proximal to first LED (2776) on the upper side of circuit board(2772). LEDs (2776, 2778) may be similar in structure and function toLEDS (2702, 2704) of circuit board assembly (2760) described above, andare configured to illuminate the undersides of window (3570) andcheckmark feature (3564), respectively, of user feedback feature (114).

Main circuit board assembly (2770) of the present example furtherincludes an opaque conformal coating (2780) that encapsulates circuitboard (2772) while leaving LEDs (2776, 2778) exposed. Opaque coating(2780) is formed of an opaque, liquid-impermeable material configured toinhibit liquid ingress and also directionally limit the illuminationprovided by LEDs. In some versions, opaque coating (2780) may be formedof a black material, such as a carbon-infused material. Opaque coating(2780) of the present example defines a first light guide feature in theform of a generally cylindrical projection (2782) that encircles secondLED (2778) and extends upwardly from circuit board (2772) to define anupper edge (2784) that is raised above an upper surface (2786) ofcoating (2780) that spans laterally across circuit board (2772). Adistal side of cylindrical projection (2782) includes a flat wall (2788)that confronts first LED (2776). Opaque coating (2780) further defines asecond light guide feature in the form of a generally rectangular recess(2790) arranged distally of cylindrical projection (2782) and in whichfirst LED (2776) is centrally positioned. Recess (2790) is defined byflat wall (2788) and a pair of laterally opposed side walls (2792) thatextend distally from flat wall (2788) to a distal opening (2794) at adistal edge of circuit board.

As seen in FIGS. 84 and 85, an inner surface (2783) of cylindricalprojection (2782) is spaced outwardly away from second LED (2778), andwalls (2788, 2792) are spaced outwardly away from first LED (2776).Accordingly, light guide features (2782, 2790) of opaque conformalcoating (2780) are configured to direct light emitted by LEDs (2776,2778) without obstructing LEDs (2776, 2778) themselves, whilesimultaneously inhibiting fluid ingress. It will be appreciated thatLEDs (2776, 2778) and the corresponding exposed portions of circuitboard (2772) to which LEDS (2776, 2778) are mounted may be coated with atranslucent liquid-impermeable coating that inhibits liquid ingresswhile permitting light transmission therethrough.

As shown in FIG. 85, cap feature (3584) of secondary body portion (3582)of lens member (3550) is sized to receive therein and thereby mate withan upper portion of cylindrical projection (2782) of opaque conformalcoating (2780). Cap feature (3584) and cylindrical projection (2782)cooperate to guide light emitted by second LED (2778) directly towardcheckmark feature (3564), such that cap feature (3584) and cylindricalprojection (2782) function as a “light pipe” structure. Simultaneously,cylindrical projection (2782) and optionally also cap feature (3584)block light emitted by first LED (2776) from reaching checkmark feature(3564). In that regard, the cylindrical sidewall of cap feature (3584)may be formed of an opaque material that inhibits light transmissiontherethrough, similar to cylindrical projection (2782).

In addition to inhibiting light emitted by first LED (2776) fromreaching and illuminating checkmark feature (3564), distal wall (2788)of cylindrical projection (2782) may be configured to deflect the lightemitted by first LED (2776) distally toward window (3570) of userfeedback feature (114). Additionally, lateral sidewalls (2792) of recess(2790) may laterally constrain the light emitted by first LED (2776) sothat the emitted light is focused directly upwardly and distally towardwindow (3570). In this manner, light guide features (2782, 2790) definedby opaque conformal coating (2780) of main circuit board assembly (2770)advantageously focus the light emitted by LEDs (2776, 2778) in thedirection of their intended target zones for illumination, with minimalor no illumination of unintended zones.

As shown schematically in FIG. 85, main circuit board assembly (2770) ofthe present version further includes a light blocking layer (2796)operable to inhibit light emitted by either LED (2776, 2778) frombleeding longitudinally through circuit board (2772) toward the opposingLED (2776, 2778). Light blocking layer (2796) of the present example isembedded within circuit board (2772) at a distal end thereof such thatlight blocking layer (2796) underlies first and second LEDs (2776,2778). In other versions, light blocking layer (2796) may be formed on atop surface of circuit board (2772). Light blocking layer (2796) may beformed of any opaque material suitably configured to inhibit lightpassage therethrough. In some versions, light blocking layer (2796) maybe formed of copper, such as the same copper that defines theelectrically conductive traces of circuit board (2772), or any othermetallic material (electrically conductive or otherwise). In otherversions, light blocking layer (2796) may be formed of a polymericmaterial, such as a material suitable to simultaneously function as asolder mask over conductive traces of circuit board (2772).

XIV. Exemplary Additional Conformal Coatings for Electrical Components

As described above, opaque conformal coating (2780) is configured toinhibit light transmission as well as protect circuit board (2772)against fluid ingress. In some instances, it may be desirable to provideconformal coatings at additional locations of control circuit (2700) toprotect against fluid ingress and also to strengthen mechanicalconnections between wires and the circuit board(s) to which they areconnected.

FIG. 86 shows an exemplary circuit board assembly (3000) configured foruse with handle assembly (100) and having a circuit board (3002) with aconformal coating (3004) of liquid-impermeable material formed about thejunction between wires (3006) and circuit board (3002). FIG. 87 showsanother exemplary circuit board assembly (3010) configured for use withhandle assembly (100) and having a circuit board (3012) with a conformalcoating (3014) of liquid-impermeable material formed about the junctionbetween wires (3016) and circuit board (3012). As noted above, conformalcoatings (3004, 3014) protect circuit boards (3002, 3012) against liquidingress while also strengthening the mechanical connections betweencircuit boards (3002, 3012) and wires (3006, 3016), respectively. Itwill be appreciated that circuit board assemblies (3000, 3010) mayotherwise be similar in structure and function to any of the exemplarycircuit boards assemblies of control circuit (2700) described above.

XV. Exemplary Features for Calibrating Tissue Gap Green Zone of UserFeedback Feature

As described above in connection with FIG. 32, fixed linear indicia(3552, 3556) of user feedback feature (114) indicate respective ends ofa “green zone” of axial spacing (or “tissue gap”) between anvil (400)and stapling head assembly (300) that enables successful formation ofstaples fired into tissue by stapling head assembly (300). Thelongitudinal position of indicator needle (1526) relative to linearindicia (3552, 3556) may be observed by the operator through window(3570) of lens member (3550) to monitor the longitudinal position ofanvil (400) relative to the boundaries of the green zone. In particular,a position of indicator needle (1526) closer to distal linear indicia(3552) indicates a larger tissue gap and a resulting taller height ofthe formed staples, as indicated by tall formed-staple graphic (3560) atthe distal end of window (3570). Conversely, a position of indicatorneedle (1526) closer to proximal linear indicia (3556) indicates asmaller tissue gap and a resulting shorter height of the formed staples,as indicated by short formed-staple graphic (3562) at the proximal endof window (3570).

During manufacture of stapler instrument (10), instrument (10) may becalibrated such that indicator needle (1526) aligns with distal linearindicia (3552) to define the distal end of the green zone. Thelongitudinal position at which proximal linear indicia (3556) is fixedmay then be calculated based on the position of distal linear indicia(3552) to define the proximal end of the green zone. In some instances,however, it may be desirable to calibrate user feedback feature (114)after manufacture and before or during use of instrument (10) so thatproximal linear indicia (3554), and thus the proximal end of the greenzone, aligns accurately with indicator needle (1526) when anvil (400) isin the fully closed state relative to stapling head assembly (300). Theexemplary configurations described below in connection with FIGS. 88-94enable such calibration.

A. Exemplary User Feedback Feature Having Sliding Shutter

FIGS. 88-90 show another exemplary user feedback feature (7000)configured for use with handle assembly (100) of instrument (10), andwhich is similar to user feedback feature (114) described above exceptas otherwise described below. User feedback feature (7000) includes acover plate (7002) configured to be positioned atop lens member (3550)at the distal end of handle assembly (100). Cover plate (7002) includesa centrally positioned rectangular opening (7004) through which linearindicia (3552, 3554, 3556), the corresponding green zone, and window(3570) of lens member (3550) are visible. Cover plate (7002) furtherincludes a checkmark-shaped opening (7006) positioned proximal torectangular opening (7004) and which is configured to providevisualization of checkmark feature (3564) of lens member (3550).

User feedback feature (7000) further includes a shutter (7010) slidablycoupled to an underside of cover plate (7002). Shutter (7010) has agenerally elongate rectangular body with a rectangular opening (7012)formed at a proximal end thereof such that opening (7012) is configuredto align with rectangular opening (7004) of cover plate (7002). A distalend of shutter (7010) includes an elongate groove (7014) configured toreceive the tip of an adjustable set screw (7008) that extendsdownwardly from cover plate (7002). Shutter (7010) is selectivelyadjustable in longitudinal position relative to cover plate (7002) tothereby locate shutter opening (7012) in a desired longitudinal positionrelative to cover plate opening (7004). In this manner, the user mayselectively obscure or reveal a desired portion of the green zone oflens member (3550) to thereby adjust the proximal end of the green zonerelative to indicator needle (1526) when anvil (400) is in a fullyclosed position, thereby calibrating user feedback feature (7000). Oncecalibrated, the longitudinal position of shutter (7010) may be fixedrelative to cover plate (7002) via tightening of set screw (7008).

B. Exemplary User Feedback Feature Having Ratcheting Shutter

FIG. 91 shows another exemplary user feedback feature (7100) configuredfor use with handle assembly (100) and which is similar to user feedbackfeatures (114, 7000) described above except as otherwise describedabove. User feedback feature (7100) includes a cover plate (7102)configured to be positioned atop lens member (3550) at the distal end ofhandle assembly (100). Cover plate (7102) includes has a rectangularcentral opening (7104) through which linear indicia (3552, 3554, 3556),the corresponding green zone, and window (3570) of lens member (3550)are visible. Cover plate (7102) further includes a checkmark-shapedopening (7106) positioned proximal to rectangular opening (7104) andwhich is configured to provide visualization of checkmark feature (3564)of lens member (3550).

User feedback feature (7100) further includes a shutter (7110) movablycoupled to an underside of cover plate (7102). Shutter (7110) has agenerally U-shaped body defining an opening (7112) configured to alignwith rectangular opening (7112) of cover plate (7102) to reveal featuresof lens member (3550). A laterally extending rib (7114) is secured at aproximal end of opening (7112) and is configured to directly contactindicator needle (1526), as described below. Shutter (7110) is slidablelongitudinally relative to cover plate (7102) and is biased distally inthe present example by a resilient member shown in the formed of acompression spring (7116) disposed at the proximal end of shutter(7110).

A ratchet mechanism (7120) of user feedback feature (7100) is configuredto releasably maintain a longitudinal position of shutter (7110)relative to cover plate (7102). Ratchet mechanism (7120) includes a pairof ratchet racks (7122), each secured to a respective lateral side ofshutter (7110) and having a plurality of ratchet teeth, and a pair ofspring biased pawl plungers (7124), each configured to releasably engagea respective one of the ratchet racks (7122). Pawl plungers (7124) maybe anchored to cover plate (7102) or to a portion of handle assembly(100) positioned beneath cover plate (7102). As anvil (400) is retractedproximally toward stapling head assembly (300), indicator needle (1526)advances proximally within shutter opening (7112) and drives againstshutter rib (7114), thereby driving shutter (7110) proximally againstcompression spring (7116) while ratchet mechanism (7120) preventsshutter (7110) from reverting distally. As shutter (7110) advancesproximally, progressively more of the green zone of lens member (3550)is visually revealed through shutter opening (7112). Indicator needle(1526) remains in contact with shutter rib (7114) during proximaladvancement such that upon anvil (400) reaching its fully closedposition, indicator needle (1526) is positioned in alignment with theproximal end of the visible portion of the green zone. In this manner,user feedback feature (7100) automatically assumes a calibrated statethroughout its use, without need for manual adjustment by the user.

C. Exemplary User Feedback Feature Having Display Screen

FIGS. 88-91 described above illustrate exemplary mechanical featuresthat provide calibration of a user feedback feature (114, 7000, 7100).In some instances, it may be desirable to incorporate non-mechanicalfeatures that provide such calibration. FIG. 91A-92B show an exemplaryuser feedback feature (7200) configured for use with handle assembly(100) and which is similar to user feedback feature (114) describedabove except as otherwise described below. User feedback feature (7200)includes a cover plate (7202) having a central opening (7204) and a lensmember (7210) received within and visible through central opening(7204).

Lens member (7210) is similar to lens member (3550) described aboveexcept that lens member (7210) includes a digital display (7212), suchas a liquid crystal display (LCD) screen, configured to digitallydisplay linear indicia (7214, 7216, 7218) and the corresponding greenzone. Digital display (7212) is controlled by control circuit (2700),which may be configured to monitor proximal retraction of anvil (400)and automatically adjust the longitudinal position of proximal linearindicia (7218) (i.e., the proximal end of the green zone) displayed bydigital display (7212) in real time during retraction. In this manner,control circuit (2700) may ensure that proximal linear indicia (7218)aligns with indicator needle (1526) visible through window (7220) whenanvil (400) is in the fully closed position. It will be appreciated thatdigital display (7212) may be further configured to display variousother types of information pertaining to surgical instrument (10) and/oruse thereof.

FIG. 92A shows user feedback feature (7200) in a first exemplary statein which indicator needle (1526) assumes a first longitudinal positionwithin window (7220) when anvil (400) is fully closed. Digital display(7212) displays proximal linear indicia (7218) in alignment withindicator needle (1526). FIG. 92B shows user feedback feature (7200) ina second exemplary state in which indicator needle (1526) assumes asecond, more-proximal longitudinal position within window (7220) whenanvil (400) is fully closed. Digital display (7212) displays proximallinear indicia (7218) in alignment with indicator needle (1526) and thusexpands the green zone proximally.

D. Exemplary Indicator Member Having Adjustable Calibration Screw

FIGS. 88-92 described above illustrate exemplary features and methods ofcalibrating a user feedback feature (114, 7000, 7100, 7200) viaadjustment of the longitudinal position of a proximal end of thedisplayed green zone to align with indicator needle (1526) when anvil(400) is in a fully closed position. In some instances, it may bedesirable to calibrate a user feedback feature via adjustment of thelongitudinal position of indicator needle (1526) to align with theexisting proximal end of the green zone.

FIGS. 93 and 94 show an exemplary alternative indicator member (7300)configured for use with instrument (10) in place of indicator members(1520, 3600), and which is similar to indicator member (3600) describedabove except as otherwise described below. As shown best in FIG. 93,indicator member (7300) includes an upright arm (7302), a snap pin(7304) projecting laterally from a lower end of arm (7302), an indicatorneedle (not shown) projecting laterally from an upper end of arm (7302),and a resilient arm (7305) projecting upwardly and obliquely from thelower end of arm (7302). An angle adjustment screw (7306) projectslaterally through an opening in arm (7302) above snap pin (7304), and anut (7308) is threadedly coupled to adjustment screw (7306).

As shown best in FIG. 94, adjustment screw (7306) is configured toextend laterally through flange opening (3672) of bracket (3650),described in greater detail above in connection with FIG. 35. Nut (7308)is configured to be tightened on the threaded shaft of adjustment screw(7306) to clamp bracket flange (3670) against arm (7302) of indicatormember (7300). The threaded shaft of adjustment screw (7306) is smallerin diameter than a longitudinal dimension of flange opening (3672) suchthat screw (7306) is longitudinally movable within flange opening (3672)when screw (7306) is loosened relative to nut (7308). Accordingly, anangular orientation of indicator member (7300) relative to bracket(3650) may be adjusted by loosening adjustment screw relative to nut(7308), sliding adjustment screw (7306) proximally or distally withinflange opening (3672), and then re-tightening adjustment screw (7306)relative to nut (7308). In this manner, a longitudinal position of theindicator needle (not shown) of indicator member (7300) within window(3570) may be adjusted to align the indicator needle with proximallinear indicia (3556) of lens member (3550), thereby calibrating userfeedback feature (114).

XVI. Exemplary Alternative Firing Trigger Having Resiliently DeflectableActivation Paddle

As described above in connection with FIGS. 30D-30E and 59A-59B,depression of firing trigger (150) by a user causes trigger paddle (158)to pivot into contact with a switch of motor actuation module (180),thereby activating motor (161) to initiate a firing sequence. Chassis(3690) of handle assembly (100) may include one or more mechanical stopfeatures configured to prevent over-rotation of firing trigger (150) andresultant damage to motor activation module (180) by compression forcesexerted by paddle (158). Nevertheless, in some instances it may bedesirable to provide paddle (158) with a resiliently deflectableconfiguration to provide an addition degree of protection againsttransmission of excessive compression force from paddle (158) to motoractivation module (180) during actuation of firing trigger (150).

FIG. 95 shows an exemplary alternative firing trigger (7400) configuredfor use with handle assembly (100) of instrument (10) in place of firingtrigger (150). Firing trigger (7400) is similar to firing trigger (150)except that firing trigger (7400) includes an upwardly extendingactivation paddle (7402) having an elongated and thinned configurationrelative to that of paddle (158). Paddle (7402) is configured toresiliently deflect relative to its neutral position shown in FIG. 95 inresponse to a threshold compression force exerted between paddle (7402)and motor activation module (180) when firing trigger (7400) is actuatedby the user. Such resilient deflection of paddle (7402) protects motoractivation module (180) from undesirable damage. Similar to firingtrigger (150), firing trigger (7400) additionally includes a mechanicalstop feature (7404) configured to contact a corresponding feature ofchassis (3690) to prevent over-rotation of trigger (7400).

XVII. Exemplary Combinations

The following examples relate to various non-exhaustive ways in whichthe teachings herein may be combined or applied. The following examplesare not intended to restrict the coverage of any claims that may bepresented at any time in this application or in subsequent filings ofthis application. No disclaimer is intended. The following examples arebeing provided for nothing more than merely illustrative purposes. It iscontemplated that the various teachings herein may be arranged andapplied in numerous other ways. It is also contemplated that somevariations may omit certain features referred to in the below examples.Therefore, none of the aspects or features referred to below should bedeemed critical unless otherwise explicitly indicated as such at a laterdate by the inventors or by a successor in interest to the inventors. Ifany claims are presented in this application or in subsequent filingsrelated to this application that include additional features beyondthose referred to below, those additional features shall not be presumedto have been added for any reason relating to patentability.

Example 1

A surgical instrument comprising: (a) a body assembly; (b) a shaftassembly extending distally from the body assembly; (c) a staplingassembly at a distal end of the shaft assembly, wherein the staplingassembly is actuatable between an open state and a closed state forclamping tissue, wherein the stapling assembly in the closed state isconfigured to staple and cut the clamped tissue; (d) a first userfeedback element configured to visually inform a user of a firstcondition of the stapling assembly; (e) a second user feedback elementconfigured to visually inform the user of a second condition of thestapling assembly; and (f) a circuit board assembly including: (i) acircuit board, (ii) a first light source coupled to the circuit board,wherein the first light source is configured to illuminate the firstuser feedback element, (iii) a second light source coupled to thecircuit board, wherein the second light source is configured toilluminate the second user feedback element, and (iv) a light guidefeature, wherein the light guide feature is configured to direct lightfrom the second light source toward the second user feedback element andsimultaneously inhibit light emitted by the first light source fromilluminating the second user feedback element.

Example 2

The surgical instrument of Example 1, wherein the first user feedbackelement and the second user feedback element are positioned on the bodyassembly.

Example 3

The surgical instrument of any of the preceding Examples, furthercomprising a movable indicator member, wherein the first user feedbackelement includes a window configured to provide visualization of themovable indicator member.

Example 4

The surgical instrument of Example 3, wherein the second user feedbackelement includes a checkmark feature.

Example 5

The surgical instrument of any of the preceding Examples, wherein thesecond user feedback feature is positioned proximal to the first userfeedback feature, wherein the second light source is positioned proximalto the first light source.

Example 6

The surgical instrument of any of the preceding Examples, wherein thefirst condition comprises a closed state of the stapling assembly,wherein the second condition comprises a fired state of the staplingassembly.

Example 7

The surgical instrument of any of the preceding Examples, wherein thefirst light source includes a first light emitting diode, wherein thesecond light source includes a second light emitting diode.

Example 8

The surgical instrument of any of the preceding Examples, wherein thelight guide feature projects outwardly from the circuit board in adirection toward the second user feedback element.

Example 9

The surgical instrument of Example 8, wherein the light guide featureencircles the second light source.

Example 10

The surgical instrument of Example 9, wherein an interior surface of thelight guide feature is spaced away from the second light source.

Example 11

The surgical instrument of any of the preceding Examples, wherein thehandle assembly includes a structure that provides the first and seconduser feedback elements, wherein the structure is configured to mate withthe light guide feature.

Example 12

The surgical instrument of any of the preceding Examples, wherein thecircuit board assembly includes a conformal coating that at leastpartially encapsulates the circuit board, wherein the conformal coatingdefines the light guide feature.

Example 13

The surgical instrument of Example 12, wherein the conformal coatingcomprises an opaque material.

Example 14

The surgical instrument of any of the preceding Examples, wherein thecircuit board includes a light blocking layer configured to inhibitlight emitted by the first light source from transmitting through thecircuit board toward the second light source.

Example 15

The surgical instrument of Example 14, wherein the light blocking layercomprises a metallic material.

Example 16

A surgical instrument comprising: A surgical instrument comprising: (a)a body assembly; (b) a shaft assembly extending distally from the bodyassembly; (c) a stapling assembly at a distal end of the shaft assembly,wherein the stapling assembly is actuatable between an open state and aclosed state for clamping tissue, wherein the stapling assembly in theclosed state is configured to staple and cut the clamped tissue; (d) afirst user feedback element configured to visually inform a user of afirst condition of the stapling assembly; (e) a second user feedbackelement configured to visually inform the user of a second condition ofthe stapling assembly; and (f) a circuit board assembly including: (i) acircuit board, (ii) a first light source coupled to the circuit board,wherein the first light source is configured to illuminate the firstuser feedback element, (iii) a second light source coupled to thecircuit board, wherein the second light source is configured toilluminate the second user feedback element, and (iv) a conformalcoating that at least partially encapsulates the circuit board, whereinthe conformal coating is configured to inhibit light emitted by thefirst light source from illuminating the second user feedback element.

Example 17

The surgical instrument of Example 16, wherein the conformal coatingcomprises an opaque material configured to inhibit transmission of lighttherethrough.

Example 18

The surgical instrument of any of Examples 16 through 17, wherein theconformal coating defines a cylindrical projection configured to guidelight emitted by the second light source toward the second user feedbackelement.

Example 19

A surgical instrument comprising: (a) a body assembly; (b) a shaftassembly extending distally from the body assembly; (c) a staplingassembly at a distal end of the shaft assembly, wherein the staplingassembly is actuatable between an open state and a closed state forclamping tissue, wherein the stapling assembly in the closed state isconfigured to staple and cut the clamped tissue; (d) a first userfeedback element configured to visually inform a user of a firstcondition of the stapling assembly; (e) a second user feedback elementconfigured to visually inform the user of a second condition of thestapling assembly; and (f) a circuit board assembly including: (i) acircuit board having a light blocking layer, (ii) a first light sourcecoupled to the circuit board, wherein the first light source isconfigured to illuminate the first user feedback element, and (iii) asecond light source coupled to the circuit board, wherein the secondlight source is configured to illuminate the second user feedbackelement, wherein the light blocking layer is configured to inhibit lightemitted by the first light source from transmitting through the circuitboard toward the second light source.

Example 20

The surgical instrument of Example 19, wherein the light blocking layercomprises copper.

XVIII. Miscellaneous

It should also be understood that any one or more of the teachings,expressions, embodiments, examples, etc. described herein may becombined with any one or more of the other teachings, expressions,embodiments, examples, etc. that are described herein. Theabove-described teachings, expressions, embodiments, examples, etc.should therefore not be viewed in isolation relative to each other.Various suitable ways in which the teachings herein may be combined willbe readily apparent to those of ordinary skill in the art in view of theteachings herein. Such modifications and variations are intended to beincluded within the scope of the claims.

Furthermore, any one or more of the teachings herein may be combinedwith any one or more of the teachings disclosed in and/or U.S. Pat. App.No. 16/583,690, entitled “Circular Surgical Stapler,” filed on Sep. 26,2019, published as U.S. Pub. No. 2020/0281596 on Sep. 10, 2020, U.S.Pat. App. No. 16/583,376, entitled “Timer Circuit to Control Firing ofPowered Surgical Stapler,” filed on Sep. 26, 2019, published as U.S.Pub. No. 2020/0281592 on Sep. 10, 2020; U.S. Pat. App. No. 16/583,381,entitled “Power Control Circuit for Powered Surgical Stapler,” filed onSep. 26, 2019, published as U.S. Pub. No. 2020/0281593 on Sep. 10, 1010;and/or U.S. Pat. App. No. 16/583,386, entitled “Electrical PotentialShifting Circuit for Powered Surgical Stapler,” filed on Sep. 26, 2019,published as U.S. Pub. No. 2020/0281594 on Sep. 10, 2020. The disclosureof each of these U.S. patent applications is incorporated by referenceherein.

At least some of the teachings herein may also be readily combined withone or more teachings of U.S. Pub. No. 2015/0083772, entitled “SurgicalStapler with Rotary Cam Drive and Return,” published Mar. 26, 2015, nowabandoned, the disclosure of which is incorporated by reference herein;U.S. Pat. No. 9,936,949, entitled “Surgical Stapling Instrument withDrive Assembly Having Toggle Features,” issued Apr. 10, 2018, thedisclosure of which is incorporated by reference herein; U.S. Pat. No.9,907,552, entitled “Control Features for Motorized Surgical StaplingInstrument,” issued Mar. 6, 2018, the disclosure of which isincorporated by reference herein; U.S. Pat. No. 9,713,469, entitled“Surgical Stapler with Rotary Cam Drive,” issued Jul. 25, 2017, thedisclosure of which is incorporated by reference herein; U.S. Pub. No.2016/0374665, entitled “Surgical Stapler with ElectromechanicalLockout,” published Dec. 29, 2016, issued as U.S. Pat. No. 10,905,415 onFeb. 2, 2021, the disclosure of which is incorporated by referenceherein; U.S. Pub. No. 2016/0374666, entitled “Surgical Stapler withReversible Motor,” published Dec. 29, 2016, issued as U.S. Pat. No.10,456,134 on Oct. 29, 2019, the disclosure of which is incorporated byreference herein; U.S. Pat. No. 10,307,157, entitled “Surgical Staplerwith Anvil Seating Detection,” issued Jun. 4, 2019, the disclosure ofwhich is incorporated by reference herein; U.S. Pub. No. 2016/0374673,entitled “Firing Circuit for Surgical Stapler,” published Dec. 29, 2016,issued as U.S. Pat. No. 10,405,855 on Sep. 10, 2019, the disclosure ofwhich is incorporated by reference herein; U.S. Pat. No. 10,194,911,entitled “Surgical Stapler with Ready State Indicator,” issued Feb. 5,2019, the disclosure of which is incorporated by reference herein; U.S.Pat. No. 10,188,386, entitled “Surgical Stapler with Anvil StateIndicator,” issued Jan. 29, 2019, the disclosure of which isincorporated by reference herein; U.S. Pat. No. 10,265,066, entitled“Surgical Stapler with Incomplete Firing Indicator,” issued Apr. 23,2019, the disclosure of which is incorporated by reference herein; U.S.Pat. No. 10,271,841, entitled “Bailout Assembly for Surgical Stapler,”issued Apr. 30, 2019, the disclosure of which is incorporated byreference herein; U.S. Pat. No. 10,226,253, entitled “Firing Assemblyfor Circular Stapler,” issued Mar. 12, 2019, the disclosure of which isincorporated by reference herein; U.S. Pat. No. 10,271,842, entitled“Anvil Stabilization Features for Surgical Stapler,” issued Apr. 30,2019, the disclosure of which is incorporated by reference herein; U.S.Pub. No. U.S. Pub. No. 2016/0374672, entitled “Method of Applying anAnnular Array of Staples to Tissue,” published Dec. 29, 2017, issued asU.S. Pat. No. 10,478,189 on Nov. 19, 2019, the disclosure of which isincorporated by reference herein; U.S. Pub. No. 2018/0132853, entitled“Circular Stapler with Recessed Deck,” published May 17, 2018, issued asU.S. Pat. No. 10,980,542 on Apr. 20, 2021, the disclosure of which isincorporated by reference herein; U.S. Pub. No. 2018/0132848, entitled“Atraumatic Stapling Head Features for Circular Surgical Stapler,”published May 17, 2018, issued as U.S. Pat. No. 10,542,981 on Jan. 28,2020, the disclosure of which is incorporated by reference herein; U.S.Pub. No. 2018/0132849, entitled “Staple Forming Pocket Configurationsfor Circular Surgical Stapler,” published May 17, 2018, the disclosureof which is incorporated by reference herein; U.S. Pub. No.2018/0132854, entitled “Circular Surgical Stapler with AngularlyAsymmetric Deck Features,” published May 17, 2018, issued as U.S. Pat.No. 10,603,041 on Mar. 31, 2020, the disclosure of which is incorporatedby reference herein; U.S. Pub. No. 2018/0310938, entitled “HysteresisRemoval Feature in Surgical Stapling Instrument,” published Nov. 1,2018, issued as U.S. Pat. No. 10,695,068 on Jun. 30, 2020, thedisclosure of which is incorporated by reference herein; and/or U.S.Pub. No. 2018/0310939, entitled “Liquid-Immune Trigger Circuit forSurgical Instrument,” published Nov. 1, 2018, issued as U.S. Pat. No.10,729,444 on Aug. 4, 2020, the disclosure of which is incorporated byreference herein. Various suitable ways in which the teachings hereinmay be combined with the teachings of the above-referenced patents,publications, and patent applications will be apparent to those ofordinary skill in the art.

At least some of the teachings herein may also be readily combined withone or more teachings of U.S. Pat. No. 7,794,475, entitled “SurgicalStaples Having Compressible or Crushable Members for Securing TissueTherein and Stapling Instruments for Deploying the Same,” issued Sep.14, 2010, the disclosure of which is incorporated by reference herein;U.S. Pat. No. 9,572,573, entitled “Trans-Oral Circular AnvilIntroduction System with Dilation Feature,” issued Feb. 21, 2017, thedisclosure of which is incorporated by reference herein; U.S. Pat. No.9,289,207, entitled “Surgical Staple with Integral Pledget for TipDeflection,” issued Mar. 22, 2016, the disclosure of which isincorporated by reference herein; U.S. Pub. No. 2014/0158747, entitled“Surgical Stapler with Varying Staple Widths along DifferentCircumferences,” published Jun. 12, 2014, now abandoned, the disclosureof which is incorporated by reference herein; U.S. Pat. No. 9,498,222,entitled “Pivoting Anvil for Surgical Circular Stapler,” issued Nov. 22,2016, the disclosure of which is incorporated by reference herein; U.S.Pat. No. 9,724,100, entitled “Circular Anvil Introduction System withAlignment Feature,” issued Aug. 8, 2017, the disclosure of which isincorporated by reference herein; U.S. Pat. No. 9,532,783, entitled“Circular Stapler with Selectable Motorized and Manual Control,Including a Control Ring,” issued Jan. 3, 2017, the disclosure of whichis incorporated by reference herein; U.S. Pat. No. 9,597,081, entitled“Motor Driven Rotary Input Circular Stapler with Modular End Effector,”issued Mar. 21, 2017, the disclosure of which is incorporated byreference herein; and/or U.S. Pat. No. 9,463,022, entitled “Motor DrivenRotary Input Circular Stapler with Lockable Flexible Shaft,” issued Oct.11, 2016, the disclosure of which is incorporated by reference herein.Various suitable ways in which such teachings may be combined will beapparent to those of ordinary skill in the art.

While the examples herein have been provided in the context of acircular stapling instrument, it should be understood that the variousteachings herein may be readily applied to various other kinds ofsurgical instruments. By way of example only, the various teachingsherein may be readily applied to linear stapling devices (e.g.,endocutters). For instance, various teachings herein may be readilycombined with various teachings of U.S. Pat. No. 8,453,914, entitled“Motor-Driven Surgical Cutting Instrument with Electric ActuatorDirectional Control Assembly,” issued Jun. 4, 2013, the disclosure ofwhich is incorporated by reference herein, and/or U.S. Pat. No.8,408,439, entitled “Surgical Stapling Instrument with An ArticulatableEnd Effector,” issued Apr. 2, 2013, the disclosure of which isincorporated by reference herein, as will be apparent to those ofordinary skill in the art. As another merely illustrative example, thevarious teachings herein may be readily applied to a motorizedelectrosurgical device. For instance, various teachings herein may bereadily combined with various teachings of U.S. Pat. No. 9,161,803,entitled “Motor Driven Electrosurgical Device with Mechanical andElectrical Feedback,” issued Oct. 20, 2015, the disclosure of which isincorporated by reference herein, as will be apparent to those ofordinary skill in the art. Other suitable kinds of instruments in whichthe teachings herein may be applied, and various ways in which theteachings herein may be applied to such instruments, will be apparent tothose of ordinary skill in the art.

It should be appreciated that any patent, publication, or otherdisclosure material, in whole or in part, that is said to beincorporated by reference herein is incorporated herein only to theextent that the incorporated material does not conflict with existingdefinitions, statements, or other disclosure material set forth in thisdisclosure. As such, and to the extent necessary, the disclosure asexplicitly set forth herein supersedes any conflicting materialincorporated herein by reference. Any material, or portion thereof, thatis said to be incorporated by reference herein, but which conflicts withexisting definitions, statements, or other disclosure material set forthherein will only be incorporated to the extent that no conflict arisesbetween that incorporated material and the existing disclosure material.

Versions of the devices described above may have application inconventional medical treatments and procedures conducted by a medicalprofessional, as well as application in robotic-assisted medicaltreatments and procedures. By way of example only, various teachingsherein may be readily incorporated into a robotic surgical system suchas the DAVINCI™ system by Intuitive Surgical, Inc., of Sunnyvale, Calif.

Versions described above may be designed to be disposed of after asingle use, or they can be designed to be used multiple times. Versionsmay, in either or both cases, be reconditioned for reuse after at leastone use. Reconditioning may include any combination of the steps ofdisassembly of the device, followed by cleaning or replacement ofparticular pieces, and subsequent reassembly. In particular, someversions of the device may be disassembled, and any number of theparticular pieces or parts of the device may be selectively replaced orremoved in any combination. Upon cleaning and/or replacement ofparticular parts, some versions of the device may be reassembled forsubsequent use either at a reconditioning facility, or by a userimmediately prior to a procedure. Those skilled in the art willappreciate that reconditioning of a device may utilize a variety oftechniques for disassembly, cleaning/replacement, and reassembly. Use ofsuch techniques, and the resulting reconditioned device, are all withinthe scope of the present application.

By way of example only, versions described herein may be sterilizedbefore and/or after a procedure. In one sterilization technique, thedevice is placed in a closed and sealed container, such as a plastic orTYVEK bag. The container and device may then be placed in a field ofradiation that can penetrate the container, such as gamma radiation,x-rays, or high-energy electrons. The radiation may kill bacteria on thedevice and in the container. The sterilized device may then be stored inthe sterile container for later use. A device may also be sterilizedusing any other technique known in the art, including but not limited tobeta or gamma radiation, ethylene oxide, or steam.

Having shown and described various embodiments of the present invention,further adaptations of the methods and systems described herein may beaccomplished by appropriate modifications by one of ordinary skill inthe art without departing from the scope of the present invention.Several of such potential modifications have been mentioned, and otherswill be apparent to those skilled in the art. For instance, theexamples, embodiments, geometrics, materials, dimensions, ratios, steps,and the like discussed above are illustrative and are not required.Accordingly, the scope of the present invention should be considered interms of the following claims and is understood not to be limited to thedetails of structure and operation shown and described in thespecification and drawings.

We claim:
 1. A surgical instrument comprising: (a) a body assembly; (b)a shaft assembly extending distally from the body assembly; (c) astapling assembly at a distal end of the shaft assembly, wherein thestapling assembly is actuatable between an open state and a closed statefor clamping tissue, wherein the stapling assembly in the closed stateis configured to staple and cut the clamped tissue; (d) a first userfeedback element configured to visually inform a user of a firstcondition of the stapling assembly; (e) a second user feedback elementconfigured to visually inform the user of a second condition of thestapling assembly; and (f) a circuit board assembly including: (i) acircuit board, (ii) a first light source coupled to the circuit board,wherein the first light source is configured to illuminate the firstuser feedback element, (iii) a second light source coupled to thecircuit board, wherein the second light source is configured toilluminate the second user feedback element, and (iv) a light guidefeature, wherein the light guide feature is configured to direct lightfrom the second light source toward the second user feedback element andsimultaneously inhibit light emitted by the first light source fromilluminating the second user feedback element.
 2. The surgicalinstrument of claim 1, wherein the first user feedback element and thesecond user feedback element are positioned on the body assembly.
 3. Thesurgical instrument of claim 1, further comprising a movable indicatormember, wherein the first user feedback element includes a windowconfigured to provide visualization of the movable indicator member. 4.The surgical instrument of claim 3, wherein the second user feedbackelement includes a checkmark feature.
 5. The surgical instrument ofclaim 1, wherein the second user feedback feature is positioned proximalto the first user feedback feature, wherein the second light source ispositioned proximal to the first light source.
 6. The surgicalinstrument of claim 1, wherein the first condition comprises a closedstate of the stapling assembly, wherein the second condition comprises afired state of the stapling assembly.
 7. The surgical instrument ofclaim 1, wherein the first light source includes a first light emittingdiode, wherein the second light source includes a second light emittingdiode.
 8. The surgical instrument of claim 1, wherein the light guidefeature projects outwardly from the circuit board in a direction towardthe second user feedback element.
 9. The surgical instrument of claim 8,wherein the light guide feature encircles the second light source. 10.The surgical instrument of claim 9, wherein an interior surface of thelight guide feature is spaced away from the second light source.
 11. Thesurgical instrument of claim 1, wherein the handle assembly includes astructure that provides the first and second user feedback elements,wherein the structure is configured to mate with the light guidefeature.
 12. The surgical instrument of claim 1, wherein the circuitboard assembly includes a conformal coating that at least partiallyencapsulates the circuit board, wherein the conformal coating definesthe light guide feature.
 13. The surgical instrument of claim 12,wherein the conformal coating comprises an opaque material.
 14. Thesurgical instrument of claim 1, wherein the circuit board includes alight blocking layer configured to inhibit light emitted by the firstlight source from transmitting through the circuit board toward thesecond light source.
 15. The surgical instrument of claim 14, whereinthe light blocking layer comprises a metallic material.
 16. A surgicalinstrument comprising: (a) a body assembly; (b) a shaft assemblyextending distally from the body assembly; (c) a stapling assembly at adistal end of the shaft assembly, wherein the stapling assembly isactuatable between an open state and a closed state for clamping tissue,wherein the stapling assembly in the closed state is configured tostaple and cut the clamped tissue; (d) a first user feedback elementconfigured to visually inform a user of a first condition of thestapling assembly; (e) a second user feedback element configured tovisually inform the user of a second condition of the stapling assembly;and (f) a circuit board assembly including: (i) a circuit board, (ii) afirst light source coupled to the circuit board, wherein the first lightsource is configured to illuminate the first user feedback element,(iii) a second light source coupled to the circuit board, wherein thesecond light source is configured to illuminate the second user feedbackelement, and (iv) a conformal coating that at least partiallyencapsulates the circuit board, wherein the conformal coating isconfigured to inhibit light emitted by the first light source fromilluminating the second user feedback element.
 17. The surgicalinstrument of claim 16, wherein the conformal coating comprises anopaque material configured to inhibit transmission of lighttherethrough.
 18. The surgical instrument of claim 16, wherein theconformal coating defines a cylindrical projection configured to guidelight emitted by the second light source toward the second user feedbackelement.
 19. A surgical instrument comprising: (a) a body assembly; (b)a shaft assembly extending distally from the body assembly; (c) astapling assembly at a distal end of the shaft assembly, wherein thestapling assembly is actuatable between an open state and a closed statefor clamping tissue, wherein the stapling assembly in the closed stateis configured to staple and cut the clamped tissue; (d) a first userfeedback element configured to visually inform a user of a firstcondition of the stapling assembly; (e) a second user feedback elementconfigured to visually inform the user of a second condition of thestapling assembly; and (f) a circuit board assembly including: (i) acircuit board having a light blocking layer, (ii) a first light sourcecoupled to the circuit board, wherein the first light source isconfigured to illuminate the first user feedback element, and (iii) asecond light source coupled to the circuit board, wherein the secondlight source is configured to illuminate the second user feedbackelement, wherein the light blocking layer is configured to inhibit lightemitted by the first light source from transmitting through the circuitboard toward the second light source.
 20. The surgical instrument ofclaim 19, wherein the light blocking layer comprises copper.